Home Made Max IV Windshield (pics and instructions)

[rothrock]

Hi all. First time poster here. I picked up my new 2006 Max IV a few weeks ago from a dealer. It was a leftover that he had. It came with a 2500lb warn winch, roll cage with seat belts, "Package A" accessories, 26" tires, and an 18hp B&S Vanguard.

Anyways, the reason I got the IV was because I have 2 boys and a wife to go riding with. After a few times out after the sunset, it got a little chilly on the trails. I decided it was time for a windshield. I wasn't about to pay $600+ on a windshield from recreative ind., so I decided to make my own.

Total project cost was about $60.00. All items were purchased from Lowe's.

30" x 60" x 1/16" thick piece of Duraplex - $35.00
9 Bungee Cords with Balls - $5.00
Stainless Steel bolts & wingnuts with stainless and rubber washers - $20.00


I started by making a pattern out of cardboard. After I got that cut, I traced it on the Duraplex. I left the "flim" on both sides of the duraplex so I could use a sharpie marker to trace the pattern. It also helps to protect it from scratching while you're moving it around and cutting it.

After I drew the pattern, I got out the jig saw with a fine tooth blade on it and started cutting. It cut very well. I placed the duraplex on the Max and marked where I wanted to drill the holes for the bolts and the bungee cords.

After drilling all the holes, I attached the bungee cords to it and marked on the Max where I needed to drill the 4 holes across the top of the dash. It's probably best to drill the first one and then put the hardware through to keep it in place. I found out that just moving a small amount on one, threw all the other holes off.

Attached are pictures for more information. I just sprayed it with the hose to wash some dust off. The drops on it will also help you see it a little easier.

I rode around with it a little bit last night and it seemed to do pretty good. I'll be doing more riding today to see how it works. I'm hoping the 1/16" is going to be enough. It seems pretty sturdy. It's supposed to be 100 times strong than glass, so we'll see. My thinking is that the bungee cords around the left, top, and right will allow it to flex around more than it would if it was fastened tight.

2010-05-19 08.45.32.jpg 2010-05-19 08.45.25.jpg 2010-05-19 08.46.05.jpg 2010-05-19 08.45.47.jpg 2010-05-19 08.45.11.jpg

[wfo]

Looks good... Try putting rain x on it ..that will keep the water from beading up.

[RPDBRADY]

Sounds like you got a good deal on that Max IV! Nice job on the windshield!

[Mike]

Welcome to the site. Great first post! I agree that you got a good deal on the Max. For my wife's windshield I used a circular saw with the blade turned around backwards to cut the plexiglass and also had good results.

[mikni]

Wow! That was a great price. I like the windshield idea. Now all I need is the roll cage!

[cueball910]

got a realy good deal nice looking windshield

[4x44dad]

Wow! That was a great price. I like the windshield idea. Now all I need is the roll cage!

I need a roll cage also

Still searching for ideas

[4x44dad]

Hi all. First time poster here. I picked up my new 2006 Max IV a few weeks ago from a dealer. It was a leftover that he had. It came with a 2500lb warn winch, roll cage with seat belts, "Package A" accessories, 26" tires, and an 18hp B&S Vanguard.

Anyways, the reason I got the IV was because I have 2 boys and a wife to go riding with. After a few times out after the sunset, it got a little chilly on the trails. I decided it was time for a windshield. I wasn't about to pay $600+ on a windshield from recreative ind., so I decided to make my own.

Total project cost was about $60.00. All items were purchased from Lowe's.

30" x 60" x 1/16" thick piece of Duraplex - $35.00
9 Bungee Cords with Balls - $5.00
Stainless Steel bolts & wingnuts with stainless and rubber washers - $20.00


I started by making a pattern out of cardboard. After I got that cut, I traced it on the Duraplex. I left the "flim" on both sides of the duraplex so I could use a sharpie marker to trace the pattern. It also helps to protect it from scratching while you're moving it around and cutting it.

After I drew the pattern, I got out the jig saw with a fine tooth blade on it and started cutting. It cut very well. I placed the duraplex on the Max and marked where I wanted to drill the holes for the bolts and the bungee cords.

After drilling all the holes, I attached the bungee cords to it and marked on the Max where I needed to drill the 4 holes across the top of the dash. It's probably best to drill the first one and then put the hardware through to keep it in place. I found out that just moving a small amount on one, threw all the other holes off.

Attached are pictures for more information. I just sprayed it with the hose to wash some dust off. The drops on it will also help you see it a little easier.

I rode around with it a little bit last night and it seemed to do pretty good. I'll be doing more riding today to see how it works. I'm hoping the 1/16" is going to be enough. It seems pretty sturdy. It's supposed to be 100 times strong than glass, so we'll see. My thinking is that the bungee cords around the left, top, and right will allow it to flex around more than it would if it was fastened tight.

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Awesome job on the windshield

[sw1tched]

looks good. I would put the windshield on the outside of the tub though so when water hits it and runs down the windshield, it doesn't end up inside the tub.