Had an old windshield = headlight protector

[John K]

HAD AN OLD WINDSHIELD that was cracked around the vent hole and one mounting hole. I was surprised that the curve of windshield and headlight were the same. I made a head light protector.
May NOT work for you. Could have bought a Show Chrome headlight protector but I made one,Take Care John K

[offcenter]

Pictures please!
Sounds like a good idea.

[John K]

Pictures, I will try to post, never done that before. May need some help.
It is blue taped till Tuesday to give the dual lock fasteners chance to hold in place. Tuesday will be a test ride as I plan on riding to help escort the Wall that Heals. I have a cousin on there, he is one of the 3095 from Ohio on The Wall.
Take Care, John K

[John K]

Pictures, I will try to post, never done that before. May need some help.
It is blue taped till Tuesday to give the dual lock fasteners chance to hold in place. Tuesday will be a test ride as I plan on riding to help escort the Wall that Heals. I have a cousin on there, he is one of the 3095 from Ohio on The Wall.
Take Care, John K

Template left on during dual lock fastners set up

Peeling template off

Dual lock fasteners space

Should have cut fastners smaller

With LEDs on

Pictures, I will try to post, never done that before. May need some help.
It is blue taped till Tuesday to give the dual lock fasteners chance to hold in place. Tuesday will be a test ride as I plan on riding to help escort the Wall that Heals. I have a cousin on there, he is one of the 3095 from Ohio on The Wall.
Take Care, John K

[offcenter]

That is very nice!
I've been reading this forum for a long time and I've never seen anything like that before.
So yours is a first!

[John K]

off center
Thank you for the compliments.
It is not perfect but I figured I would share with others with a little thought & time maybe they can protect their obsolete, expensive heahlight. With the old windshield & headlight being shaped closely to the same made the job that much simpler.
Take Care. John K

[Bonnie and Clyde]

So did you use a heat gun for the bend?

Looks great, thanks for posting up

[John K]

No heat applied
The shape and curve of the old windshield is almost exactly shape and curve of headlight & position lights. I was surprised.
Cover was only off position lights about half an inch ( if that ), very little hand pressure needed to fold flat against position lights.
I taped the cover, template & fasteners on for a few days to help fasteners stick.
Dual lock fasteners are holding the cover in place, so far.
I expect no problems but test will be today when I fly down the highway.
Hope this helps
John K

[John K]

How I made headlight protector from Old Windshield;
I used blue painter's tape and covered headlight & position lights, went a little past outside edges
Started at bottom and went up ( proably could go top to bottom ). Covered all short pieces with longer pieces on top of to hold them
I even ran tape straight up and down to make template more rigid, proably overkill but I had the tape. After all it was my first time.
I used my finger to find imprint of the edges all around. Then used a marker to mark the edges of the lenses
Marked center of blue tape template by using center bar of chrome air intake under headlight
Found center of OUTSIDE of windshield
Pulled template off as one piece ( mine pulled off bottom to top ) and used scissors to cut on the marker line all the way around
Lined the center marks as close as possible and stuck template on OUTSIDE of windshield
Turn windshield over on soft surface ( folded towel)
Put blue tape next to edge of template ( on inside of windshield leave room for saw blade & so u can see template edge ) inside and out so Jig saw wouldn't scratch windshield. NOTE: Two layers was NOT enough so I put duct tape on top of the blue tape. Was able to cut windshield and move this tape combination to the next cut area. Added tape as needed for protection. All tape is going to be pulled off and thrown away
Use a Jig saw blade designated to cut plexiglass. Cut slowly using very little pressure, let the blade do the cutting
Sanded edges with 180 grit with electric sander.
Done
I know a lot of details but I wish to cover every step I did so you can cut an OLD WINDSHIELD = HEADLIGHT PROTECTOR
Dual lock fastners are the size of a penny. Wished I used a dime. Traced circle with fine point marker and cut out 8 pairs with scissors
Hope this works for you. Have fun and Take Care John K

[Bonnie and Clyde]

well done! Thanks for the step by step

[John K]

Thanks for the compliments.
Hope the step by step helps someone.
Take Care John K

[Frayer2020]

So what u used a the top part of windshield and cut it to fit

[John K]

Great question, I didn't cover that part. YES I cut the top of the windshield as the bottom was cracked around mounting hole and vent hole.
I put the bottom edge of the template on the windshield on the OUTSIDE at the factory edge.

Seeing how it was a tall & wide windshield, I believe 3 inches wider and 4 taller, I will be able to cut another headlight protector for a friend's 1500. I gave him a tinted, vented, with an upper lip out windshield for his new to him Wing, a few months ago. He saw the article & protector today, we agreed to trade his old windshield for a protector. So I will be cutting again.

[John K]

Template taped to outside of windshield

[attachme

Inside protection tape from saw

I should have protected area ( duct tape ) between 2nd head light protector and vent then I could have gotten 3 out of this oversized 3/16 thick windshield.

[Can68]

I have an old windscreen that is split down one side. Not sure why I never threw it out?

Except that I am a pack rat and have a shop full of stuff I never throw out. Drives my better half crazy, but she won't approve a sea can in the back yard (yet).

I never thought about how vulnerable the front light is or how hard (costly) it would be to get a replacement. This will be a great project for this winter when the snow flies.

[John K]

I had the old windshield in the attic of the garage for over 5 years, oh no I must be a pack rat also....

Atleast one less thing her new boyfriend will have to wonder why I kept when I pass away. Lol

If I can help you in any way just ask, except shoveling snow; that is why they make snowblowers

Do NOT get in a hurry while cutting, let the blade do the work

Good luck & Take Care

[John K]

off center
Thank you for the compliments.
It is not perfect but I figured I would share with others with a little thought & time maybe they can protect their obsolete, expensive headlight. With the old windshield & headlight being shaped closely to the same made the job that much simpler.
Take Care. John K