Cutting in a windshield vent

[dan filipi]

This is a vent from chromeworld.com, $50 delivered.


I've never done this before so I wasn't sure what the drill speed should be or type and size bits or which jigsaw blade would be best
so I cut it in on a old windshield first.
Anyone can offer input on better ways or tips to get this done please do.

Using a large regular universal drill bit didn't work too good drilling the plastic:

A step bit worked much better at a medium speed: :yes:

Tape the screen off good to prevent scratches when cutting with the jigsaw and measure up from center line of the trim and trace the template:

Drill some pilot holes:

Cut out with the jigsaw. I used a fine blade at high speed.
While cutting, avoid sharp turns in direction of the blade and stop the blade before removing it from the cut.
Take it slow and don't force it.

Test fit the front half of the vent. I had to trim some at the top corners. For this I used a dremel with a pointed stone.

Pull all the tape off.
Since I'm working this alone I taped the front half to the windshield to hold it in place while putting the rear half on with the 2 screws.

So that's basically it.

There's no gasket or sealer of any kind or even mention about it in the instructions but when I sprayed the windshield down with water it goes right thru so I'll seal it later on with clear silicone. For this a helper will be needed to hold one side in place during assembly so silicone doesn't end up all smeared on the windshield which will no doubt be a bear to clean off.

Closed:

Open:

The vent looks nice installed but there's one little problem.
Evidently my windshield and the stock 1100 windshield is thicker than a 1500 windshield this vent is designed for.
Problem I ran into is the top of the vent is suppose to lock together in a tongue and groove type of thing.
Since my shield is thicker that aint gonna happen.
I put it together without locking the top together and it seems fine with only the 2 screws holding the halves together.

No time to test this weekend but I'm looking forward to the first freeway ride. Sure hope it reduces buffeting and wind noise!

 

[stratocat]

Looks good Dan. :good: Where's Goldmember when you need him?. :whip: :smilie_happy: Just kiddin ya. (I don't want to start another round on corpral punishment :heat: . I'm anxious to know how the road test goes.

 

[AApple]

Looks pretty kewl to me. :good: I wonder tho...will it seal well in the rain with it closed? Not that you're not gonna get wet anyway, since yer riding in the rain, but, me concern is the stereo(or gauge panel, in your case) getting swamped. Then again...I guess that's what duct tape is for, right? :smilie_happy:

How much time did it take ya to actually do the install, not counting the "practice" time?

 

[joedrum]

okay windsheild instalation take 33.... :smilie_happy: :smilie_happy: :mrgreen:

 

[Flinx]

Interesting writeup. I'm kinda curious as to how well it works. Since I now need to replace my windshield this might just be the perfect time to install a vent.

 

[dan filipi]

Good question about rain coming in when open.

Fortunately we dont get much rain :whistling:

Install took about an hour.

 

[toytender01]

:hi: We non't get much RAIN here....BUT we do get some liquid sunshine like right now!!! :smilie_happy: :smilie_happy: Bob

 

[dan filipi]

Tested the vent today on a freeway run.

Closed= helmet noise and buffeting
Open= helmet noise and buffeting

I felt very little if ANY difference other than feeling air blowing thru the vent.

IMO, the guy who wrote that up about equalizing pressure behind the windshield would reduce buffeting and wind noise was talking theory and out of his A**

 

[joedrum]

now now dan .....hmmm alot of work for nothing....seems like good work to.....but im getting the feeling this is the last windshield vent you will mess with ...obviously you have a strong opinion now from experience :Awe: :headscratch: :Awe: oh2: :mrgreen:

 

[slabghost]

It has been my experience with several make / models of bikes. If the shield is adjust at the right height and angle that the air is deflected over and around you there is virtually no buffeting at all. It may be you are sitting too far back of a shield too short for you. Try a ride leaning fwd. A little closer to the shield and lower. If this eliminates the problem. Maybe adjusting the fairing to nose down a few degrees is the answer. Or maybe a slightly taller shield.

 

[Omega Man]

That vent is tiny for such a large surface(fairing and screen together), something twice the size might have a chance to reduce the buffeting but that would probably weaken the windshield. :Awe:

~O~

 

[AApple]

Ya sure ya didn't install it upside down? :smilie_happy: :smilie_happy: :smilie_happy:
I bet it will make a difference next summer, in the 100 deg heat... :heat:

 

[joedrum]

after dans mess with the step drill and the jigsaw and all that plastic and tape ...oh and outcome ....hes just ripe for all this ridicule :smilie_happy: :smilie_happy: :mrgreen:

 

[dan filipi]

I enjoyed custom fitting it and all but was hoping for some improvement.

If I move forward in the seat and dip my head down a bit like riding a dirt bike all the helmet noise is gone but
that's been the case with the original shorter shield as well as a taller shield.
I don't know.....it hopeless lol.

There are probably other factors involved like the fairing design itself, mirrors etc.
Guess I'll just have to live with it.

 

[AApple]

I've seen some windersheilds here that have wind deflectors on the sides of them, similar to the ones that go on the fairings. Wonder if those make any difference in the buffeting?

 

[fastmover83]

I've always had good luck with using an adjustable speed saber saw with a 36 tooth per inch upward cut blade at the lowest speed setting I can get away with for cutting windshields. If your cutting and or need to reshape a shield you can also can also use a 4"-4 1/2" angle grinder with a metal cutting disk to rough out and shape the shield after cutting, but this is only for those with experience with angle grinders, or it can get away from you. There is a way to modify a drill bit by changing the angle of the cutting surface to prevent it from grabbing and cracking the shield, but I don't remember the new angle, maybe someone else knows this trick. It's been my experience that side wings on a windshield will reduce turbulence behind a windshield and provide a quieter ride, however that still air can hold a lot of engine heat on hot days and they will also cause a vortex behind the rider which can suck a lot bugs and other debris in from the slipstream that would have normally gone on by, and if you are carrying a passenger most of it will hit them, because they will not be in the still air. If you spend some time at your local bike scrapyards you might luck out and find a set of brackets from the adjustable ones that were made in the 70's-80's. they work much better then the stationary ones.

 

[thewhiterhino]

I got rid of most of the annoying sounds on mine by taking the radios out and putting them in a box... :smilie_happy: :smilie_happy: :smilie_happy: :smilie_happy: :smilie_happy:

 

[Piper]

I think you are probably referring to these Apple. They were on the bike when I bought it and are labeled from Drag Specialties but their website doesn't have anything like them now. The windshield must be pretty old because it is made of the old style plexiglass that is .187 thick. I am going to replace it with the new type lexan that is .125 thick this winter because of the crack in the lower right corner. I already replaced the right vent wing because of a crack.
I really don't notice any buffeting with wing vents set the way they are in the pics except in a strong crosswind but I rarely go over 65 MPH. I can talk easily to the passenger up to about 50 or so and then the wind noise gets a little loud. On a really hot day they can be turned all the way in and you get a really nice breeze, almost like not having a windshield at all
I work with lexan and other brands of the new polycarbonates a lot and have the special tools and drill bits. I use a band saw most of the time.
If anybody can figure out what to use for the pivots, I would be glad to cut out the pieces for them.




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[Omega Man]

Are you going to sell it when replaced(hint)?

edit - Piper...your wing is so beautiful I hate you.

~O~

 

[Piper]

Lol.....sounds like you and my ex-wife could be friends, you have at least one thing in common

Have you ridden across the new by-pass bridge out at the dam yet? I just got to do that. I probably would leave fingerprints on the handlebars if they werent foam. I was out there in March and was watching them build the road deck. 900' drop without using any safety harnesses. Yikes!
It's got to be an absolutely fantastic view....