Bikernet Innovations--Backward Techs

Photos by Sin Wu

Yep, these techs will be backwards. I just rolled in from Arizona after the first 1,000-mile test ride after installing highbars, performance parts, and modifying the windshield to fit the highbars. So why publish the techs backwards starting with the windshield? We're lazy. This one will be short and the next two, since Frank Kaisler was involved, will be mammoth techs with thousands of photographs. Hang on for them, but if you've installed highbars on a Softail or a King model and have long arms like myself, the windshield may be a problem to attach, but there's a careful, simple cure.

First put the shield in place and decide if you can endure a handlebar adjustment or not. If you pull the bars back in line with the front end, the windshield will fit without a problem. You might check it for 80 mph flexing which could cause rubbing against the bars, cables, brake hoses or wiring (if you didn't run the wires internally). I took short wire ties and held small soft stripes of rags around the cables that would have been damaged.

So I shoved the bars forward until the windshield would have fallen off the front-end. I'm not a big fan of windshields, but when you plan a ride through a 1,000 miles of rain, cold and wet highways, it's a plus. I used the adjustable windshield from Harley-Davidson which allowed me to raise or lower it. I discovered that the lowered position is actually more comfortable in the rain. If I had raised it, I would have looked through the shield which was scattered with water and streaks. Visibility sucks and distraction was overwhelming, so I lowered it and my visibility was perfect while still maintaining the comfort and protection of the shield.

So what the hell did I do? I cut scallops in the plastic shield. First I marked off the area of the shield that had to be removed with 1/4-inch masking tape and began to grind through the plastic with a bench grinder, the finer of the two stones. I took care to keep the edge of the plastic aimed down so the stone wouldn't grab the sonuvabitch and crack it. I ground one corner then the next to search for a basic rounded feel. I avoided sharp edges or grooves that could crack. Since this was no perfect established science, I took my time slicing notches then slipping the windshield into place. I went back and forth to the grinder over and over. You might want to wear a breathing filter during this process and eye protection.

Once I was close to the finished area on one side, I took the windshield to the vice and with leather pads on either side of the mounting bracket clamped it down. Then with a high speed drill and a burr bit began to cut and shape some more. This, I found was difficult and took care not to allow the bit to grab and cut into the clear surface, but I was able to clean the edge some more. I re-installed the shield again and determined that I was damn close.

Keep in mind that this was a last minute operation on Thanksgiving day, between writing projects and packing for a run to the desert. As the evening closed in it began to rain, a rarity in this neck of the woods. I jogged in the house and flipped on the weather channel. The gods of the Roulette table had decided that I was not supposed to ride this weekend. The only rain east of the Mississippi was dead over the 10 interstate from Los Angeles to the Arizona State line. That made the windshield project even more paramount. I dashed back to the garage.

Once I was close to the necessary fitment, style and precision matching became a consideration. I ran a piece of masking tape up the side of the stainless steel strut straight up the shield as a measuring guide. Then I measured up from the horizontal strut to where the cut began. With these measurements I was able to compare them on the opposite side for an even scallop into the shield. I went back to the grinder and to the burr device for the final shaping. I continued back and forth a dozen times from the grinder then the high speed drill and back again. Once I had it nailed down, predominately with the grinder, I used an emery bit to smooth the edge of the Plexiglas.

That completed the cutting and shaping although the unit didn't lock entirely into place. I knew that once on the road the wind would prevent it from escaping. One small wire tie held the spring lock on the detachable windshield to the clutch cable for added insurance. Just under 1,000 miles later I pulled back into San Pedro with a completely successful ride under my sore ass, proving that careful mods to the Plexiglas windshield are completely possible. Rah, rah.

--Bandit