DIY BMW 1200 GS Lexan protector for the head lamps

The first project for the 1200 GS after getting it home from the dealer was to protect the $300 headlamp. This is accomplished with a piece of lexan from Home Depot.

Materials for the project:
1- Lexan sheet
1- Manila Folder (template material)
2 - 1/2" Stainless Ancor Clamp
2- 1/4 20 stainless screws, washer and nuts

Tools:

• Scissors
• Marking pens (Dual tipped Sharpies work great)
  
• Drill with 1/4 bit
• Jig saw with metal blade
• File
• Sandpaper
  

The head lamps on the BMW 1200 GS are a pretty odd shape so making a pattern is the best way to do the layout. I used the manila folder for tracing out the pattern, then cut the pattern out with scisors. You would like your head lamp protector to follow the lines of the head lamp pretty well so that reflection from the light is not thrown up on the wind screen.

Once the pattern is placed on the lexan sheet then cut out with the jig saw.
Use the file to clean up the saw marks then use the sand paper for final smoothing

Now that you have your final shape take the clamps and place them on the metal bar in front of the headlamp. Place the cut out lexan sheet in place and mark the holes. Drill the holes.

Remove the protective sheeting from the lexan sheet and use the 1/4 x 20 screws to mount on the bike with the clamps.
You are Done now go for a ride.

Once