You will need :

- 50cm x 50cm x 3mm transparent polycarbonate.

          I was lucky enough to find a sheet which corner had been damaged, so I had it for 25% the normal price

- 1m of 10mm x 1mm aluminium stem

- 1m of transparent 5mm OD hose

              available in pet shops for aquarium air piping

- 2 motorbike mirrors with a threaded link between the stem and the mirror ball joint.

Mine are Suzuki Bandit accessories

- Threaded (rivnuts) and classical rivets

- M4 stainless screws 

Step 1 : Make a template

Using cardboard, scissors and duck tape, make a template of 1 of the screens. Be precise on the scuttle / screen interface : that detail will make your work look "pro". Or not.

If you wish to be able to go back to windscreen (see "lessons learnt" at the end), locate the wiper shaft position and make a suitable hole.

You then can make the other side's template by turning this one upside down. Be careful for the wiper shaft hole : they are not symetrical.

Note : due to copyright issues, I can't post cardboard template images. See the website of the rights owner. They ask for huge fees to anyone who uses their revolutionnary concept.

Step 2 : Cut

Quite easy with an angle grinder with discs for metal. The melted polycarbonate breaks fine along the cutting line. Gently file the edge with sandpaper. 

/Portals/14/Blog/Files/27/98/from%20LHD%20passenger%20seat.jpg%20

From the LHD passenger seat : clean -and safe- edge.

 Step 3 : Cut and bend aluminium legs

Make 3 legs for each screen.

To be able to revert to windscreen, set the right and left legs on the windscreen rubber gasket footprint on the scuttle.

The center leg will be located as close as possible to the scuttle / bonnet junction, and go under the bonnet (you will have to cut 1.5cm of the rubber band under the bonnet.

Step 5 should help to make it clearhttp://my.lotussevenclub.com/Providers/HtmlEditorProviders/Fck/fckeditor/editor/images/smiley/msn/confused_smile.gif.

Step 4 : Protect against screen / scuttle interference

Use transparent 5mm OD tube.

Step 5 : attach legs to screens and legs to car

Legs to screen : use 4mm rivets and washers. Sequence : rivet - screen - washer.

/Portals/14/Blog/Files/27/98/rivet.jpg%20

 Rivet from "inside". Note the washer.

 Legs to car : use 4mm rivnuts and stainless screws

 http://my.lotussevenclub.com/Portals/14/Blog/Files/27/98/scuttle.jpg

L-shaped legs linked to the scuttle with rivnuts

Central leg : go under the bonnet !

 /Portals/14/Blog/Files/27/98/central1.jpg%20  /Portals/14/Blog/Files/27/98/central2.jpg%20

Views of the central legs. Remove 1.5cm of the foam strip. Rivnut + 4mm stainless screws in the bulkhead.

 Step 6 : Wide-track mirrors

As said before, you need mirrors with a threaded link between the stem and the ball joint. That point will be the "head" of the tripod. Being a M6 thread, you will need to drill 6⁺mm holes in the aluminium stems. The most difficult is to bend the stems to the right shape, but a little fiddling and 2 spanners should be enough.

The three legs of the tripod will be :

1- The mirror stem, in the rearmost stanchion hole

2- An aluminium stem, from the front stanchion hole to the "head"

3- Another aluminium stem, from the external screen L-sahped leg to the "head".

 /Portals/14/Blog/Files/27/98/side.jpg%20   /Portals/14/Blog/Files/27/98/tripod.jpg%20

 /Portals/14/Blog/Files/27/98/tripod2.jpg%20

Re-use stanchion holes !

Final result :

 /Portals/14/Blog/Files/27/98/final.jpg%20

Lessons learnt

1- Use polycarbonate. My first attempt was with acrylic. Much cheaper, but prone to become brittle exposed to UV. They lasted less than 1 year. My polycarbonate ones are now 4 years old and still OK.

2- Never mind the wipers shafts. Never mind the rivnuts position. You will NEVER revert to windscreen.

3- When I do a good job, I should always take step by step pictures. There will come a time when I will want to share it, and words are never explicit enough. Especially in english.

The question is : How to know BEFORE that it will be a good job http://my.lotussevenclub.com/Providers/HtmlEditorProviders/Fck/fckeditor/editor/images/smiley/msn/confused_smile.gif ?