Fabrication of windshield

Cvans · 08-27-2014, 01:36 PM

After going on a few evening rides and getting plastered with bugs the decision was made to come up with a wind shield. My G1 has a G2 front body mounted on it so this should work for all G2 to G9 carts. I used the frame for the top as the frame for the windshield. The bottom of the top frame is now the top of the windshield. The frame was cut to the desired height and bolted to the body mounting bolts. This one is cut so I'm looking over the top of the windshield. The wind flow carries the bugs over my head.
If there is an interest in this I can add more photos and instructions.

Field6565 · 08-27-2014, 02:03 PM

Real nice Chris! Looks like it belongs there. Good work.

duramax · 08-27-2014, 09:28 PM

I did this once... if the screws are tight the plexi will crack when it expands over time I drilled a larger hole & used a rubber grommet to help prevent cracking.

Cvans · 08-27-2014, 09:50 PM

The Lexon is mounted with plastic metal cored fasteners and rubber idolaters. Very little pressure on the Lexon and it can float on the fasteners yet does not vibrate. Run it down minimum maintenance roads with no problems yet.
Lexon is not as brittle as Plexi-glass.

JcXtreme72 · 10-29-2014, 11:10 PM

I love your front bumper and that windshield is cute as crap. You should post step by step pics if you can.

ericmiyako · 10-30-2014, 01:13 AM

I like the looks of a topless two-seater! You did a great job!

Swan · 10-30-2014, 06:40 AM

looks good

Mike Mac · 10-30-2014, 07:12 AM

Nice job on your window and front bumper!!

What size rectangular tubing is the front bumper? I may be able to get you plastic caps to cap them off!! If you'd like?

Cvans · 10-31-2014, 11:08 AM

Thanks for the compliments. The front bumper is 1 1/4" x 2 1/2" x 14 ga. It's kind of an odd size as it doesn't actually measure that. About a 1/16th " under O.D. both ways. I could weld caps on there and may do so later. With them open there is little to no chance of rusting.The arch over the lights is 1 1/4" tube and was part of some old lawn furniture. The lights are farm implement lights and do a good job at night. They are available at NAPA. The bumper was sprayed with truck bed liner.
The windshield has worked out well so far with no cracks after many miles of use on gravel and low maintenance roads. Without it my hat was blowing off but now the wind actually pushes my hat down on my head.

I can't make up my mind whether I should ad another bumper tube just below the first one or not.

Mike Mac · 10-31-2014, 01:47 PM

Next time I go to "Outwater Plastics" I will see if the have them. Or go there on line!!

08-27-2014, 02:03 PM	#2
Field6565 Gone Wild Join Date: Oct 2010 Location: Pittsburgh Pa Posts: 1,551	Re: Fabrication of windshield Real nice Chris! Looks like it belongs there. Good work.

08-27-2014, 09:28 PM	#3
duramax Gone Wild Join Date: Mar 2014 Location: S.W. Florida Posts: 302	Re: Fabrication of windshield I did this once... if the screws are tight the plexi will crack when it expands over time I drilled a larger hole & used a rubber grommet to help prevent cracking.

08-27-2014, 09:50 PM	#4
Cvans Gone Wild Join Date: Apr 2013 Location: Eastern SD. Posts: 276	Re: Fabrication of windshield The Lexon is mounted with plastic metal cored fasteners and rubber idolaters. Very little pressure on the Lexon and it can float on the fasteners yet does not vibrate. Run it down minimum maintenance roads with no problems yet. Lexon is not as brittle as Plexi-glass.

10-29-2014, 11:10 PM	#5
JcXtreme72 Gone Wild Join Date: Jan 2011 Location: Las Vegas, Nevada Posts: 1,942	Re: Fabrication of windshield I love your front bumper and that windshield is cute as crap. You should post step by step pics if you can.

10-30-2014, 01:13 AM	#6
ericmiyako Not Yet Wild Join Date: Jan 2014 Location: Innerarity Island, FL Posts: 42	Re: Fabrication of windshield I like the looks of a topless two-seater! You did a great job!

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10-30-2014, 06:40 AM	#7
Swan Cave Dweller Join Date: Apr 2013 Location: Always On The Move Posts: 22,217	Re: Fabrication of windshield looks good

10-30-2014, 07:12 AM	#8
Mike Mac G8 Specialist Join Date: Jun 2009 Location: Phoenix Posts: 7,799	Re: Fabrication of windshield Nice job on your window and front bumper!! What size rectangular tubing is the front bumper? I may be able to get you plastic caps to cap them off!! If you'd like?

10-31-2014, 11:08 AM	#9
Cvans Gone Wild Join Date: Apr 2013 Location: Eastern SD. Posts: 276	Re: Fabrication of windshield Thanks for the compliments. The front bumper is 1 1/4" x 2 1/2" x 14 ga. It's kind of an odd size as it doesn't actually measure that. About a 1/16th " under O.D. both ways. I could weld caps on there and may do so later. With them open there is little to no chance of rusting.The arch over the lights is 1 1/4" tube and was part of some old lawn furniture. The lights are farm implement lights and do a good job at night. They are available at NAPA. The bumper was sprayed with truck bed liner. The windshield has worked out well so far with no cracks after many miles of use on gravel and low maintenance roads. Without it my hat was blowing off but now the wind actually pushes my hat down on my head. I can't make up my mind whether I should ad another bumper tube just below the first one or not.

10-31-2014, 01:47 PM	#10
Mike Mac G8 Specialist Join Date: Jun 2009 Location: Phoenix Posts: 7,799	Re: Fabrication of windshield Next time I go to "Outwater Plastics" I will see if the have them. Or go there on line!!

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