Have to make a fairing screen

[map]

Due to the bike falling over and cracking the perspex screen I need to source a new one.

This is a winter hack Kawasaki GT550 with a massive aftermarket fairing that's non standard. Will try for pictures if I can.

Anyhow, old screen is shaped and 600m wide, about 460mm high and 4mm thick.

So asking where I can source the perspex. Tried eBay and 600mm perspex is thin on the ground. Any other sources or any other materials?

Also any advice on how to cut/shape the stuff? I understand a hot air gun may be useful to help shape/bend it. Cutting I'm not sure about.

Any help and advice appreciated.

Thanks in anticipation, MAP
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...and the whirlwind is in the thorn trees, it's hard for thee to kick against the pricks...
Gibbs, what did Duckie look like when he was younger?

[demon9374]

Dremel/Hot knife to cut it?

Boiling hot water might help it soften up abit aswell.

[dodgydog]

Wickes sell sheets of perspex. Easy to cut with their trimming knives, dunno about shaping but it's cheap enough to have a go with a hot air gun.



Dog
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[Rogerborg]

Hmm, looks like you might have to go to 1000mm x 500mm x 4mm which gets pricey. Try searching for variant like 100cm and 1m.

Cutting, I use a hacksaw. I tried a jigsaw but it melted the edges of the perspex. You could try a knife, but even 4mm is pretty thick.

Shaping, I use a paint stripping hot air gun. A powerful hair dryer might work - it's worth a try.

When bending, don't try to force it, just keep applying heat evenly over the area of the bend - don't put the heat source too close or keep it in one place or the perspex will bubble. When it becomes malleable, it's quite a distinct transition, and it can then be bent very easily. You'll want to hold it carefully in place until it's cooled down again or it will tend to relax back towards flat.

Just be patient and you'll get it done, I find it quite therapeutic.
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[G]

I cut my 6mm lexan (apparantly bullet proof and that thickness - perhaps a little more than I needed!) with a jigsaw on a slow settings I think.

I didn't do shaping, but did consider it. I was going to use two strips of metal raised above and a blow torch to heat the line I wanted to bend.