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Homemade Bashguard
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Author:  nteague1 [ Fri Jan 07, 2011 4:29 pm ]
Post subject:  Homemade Bashguard
I just finished making my own bashguard from a 3/8" thick sheet of Lexan. Working with a bulletproof material wasnt easy and the end result may not be as pretty as what you can buy in the stores, but damn was it fun to do.

If anyone wants some tips on making their own, or if anyone wants to share some of their own experiences in making their own bashguard, speak up.

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Author:  Sultan Ali [ Fri Jan 07, 2011 4:34 pm ]
Post subject:  Re: Homemade Bashguard
That looks pretty good knowing the fact that it's so hard to cut through the sheet.

Nice job and why don't you make it a full report of the cutting tools that you used and .............

Now it's time to go out and put it into the test. Good luck.

:cheers:
Author:  DWill [ Fri Jan 07, 2011 4:34 pm ]
Post subject:  Re: Homemade Bashguard
That actually looks pretty nice; nice work.
Author:  nteague1 [ Fri Jan 07, 2011 4:56 pm ]
Post subject:  Re: Homemade Bashguard
Sultan, my methods were very crude.

I created the design on graph paper using a compass and a ruler and a rough tracing of the big chainring I took off.
Then I transfered the design onto the lexan using the sharp end of the compass.
I used a hole saw to cut the center hole and a drill press for the bolt holes (2 sizes to sink the bolts) and ventilation/weight saving holes.
I painstakingly used a dremmel with a drill bit to drill holes all around the outside edge to cut it out of the sheet and then used a metal file to smooth the shape.
I filed the inner and outer edges and also the "slot" where the crank goes and then dremmeled the whole thing with a sanding bit to smooth everything.

The biggest thing to watch for is making sure your hole saw/drill bit/file dont melt the lexan.
Author:  Los [ Fri Jan 07, 2011 5:41 pm ]
Post subject:  Re: Homemade Bashguard
We have a MccGuyver section! This defines it to a T !
Author:  Throttlepimp [ Fri Jan 07, 2011 6:04 pm ]
Post subject:  Re: Homemade Bashguard
nteague1 wrote:
Sultan, my methods were very crude.

I created the design on graph paper using a compass and a ruler and a rough tracing of the big chainring I took off.
Then I transfered the design onto the lexan using the sharp end of the compass.
I used a hole saw to cut the center hole and a drill press for the bolt holes (2 sizes to sink the bolts) and ventilation/weight saving holes.
I painstakingly used a dremmel with a drill bit to drill holes all around the outside edge to cut it out of the sheet and then used a metal file to smooth the shape.
I filed the inner and outer edges and also the "slot" where the crank goes and then dremmeled the whole thing with a sanding bit to smooth everything.

The biggest thing to watch for is making sure your hole saw/drill bit/file dont melt the lexan.


Props to you for sure. As the production manager of a plastics fabrication job shop I know what goes into working with polycarbonate.

Please no one else do this. Contact me, I have access to CNC machines and we have material scraps in stock. Swing by the shop in Mirmar after 4:00 and we can knock one (or five) out in 30 mins. Bring beer, micro brew, no IPA... ales.
Author:  Los [ Fri Jan 07, 2011 6:26 pm ]
Post subject:  Re: Homemade Bashguard
Hmm. I dont need a bashguard but I do work in Miramar and drink beer..... as a matter of fact Im stuck in Miramar now!
Author:  noissiM [ Fri Jan 07, 2011 6:32 pm ]
Post subject:  Re: Homemade Bashguard
Looks good! Last time I cut a 3/8" sheet of lexan... don't ask what I used it for, I used a jig saw.

I once had a 44t super charger that I milled down to a 38t using a brake lathe. That was messy.
Author:  shano [ Fri Jan 07, 2011 6:33 pm ]
Post subject:  Re: Homemade Bashguard
I was going to suggest doing a run on the water jet if enuf peeps interested but throttlepimp gots the ticket. If u guys need a 3d rendering I can make up a solidworks model un pronto, just send me the dims
-s
Author:  shano [ Fri Jan 07, 2011 6:35 pm ]
Post subject:  Re: Homemade Bashguard
P.s. nteague- nice job!
Author:  ValE [ Fri Jan 07, 2011 8:12 pm ]
Post subject:  Re: Homemade Bashguard
that does look awful sweet! Nice job, man!
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