[Zedn]

With money a bit tight at the moment due becoming a father last week (yay!), i decided to have a go at making my own windscreen frame from stainless. I had half a sheet of 1.5mm stainless left over from my fuel tank so thought it cant hurt to give it a try.

I started out by buying the glass from o'brien for $140 to use for the mock up. I used some cardboard to make up templates for each of the pieces. I then cut these out and traced onto the stainless sheet.



I dont have a plasma cutter so i had to cut out each piece with a 4" angle grinder. It took some time but worked ok. I then clamped each matching piece together and smoothed out with the grinder.



Pieces were then clamped to the glass to hold the curves for tacking.







After tacking, the fram was removed from the glass so that i could finish weld it without heating the glass and melting the rubber. The welding was all fused except for a little bit of mig wire used as filler where any gaps were. Im glad i didnt use to much filler because it is a different colour when polished.

I was very careful with the finish welding because i was worried about warping. I just did small runs at a time leaving gaps in between and then going back and filling in. It still warped but i was able to get it back by bending it.




After welding came the slow part. I ground the welds down with the grinder using a 60grit flap wheel. I then used a hand file to file the whole thing flat then sanded with 120, 240, 320, 400, 600 and polished it up.








I am happy with the finished product, just need to finish making the side posts and its ready to install.

Unfortunatly i did crack the glass. Stupid it wasnt from the frame but my careless placement of my knee