DRZ/DR DIY Windscreen
DIY Dual Sport Windscreen: The “Tote Hack” That Actually Works
I recently stumbled across a video (posted below) detailing a DIY Trash Can Windscreen as part of our DRZ-400 Adventure Build. It’s a genius budget mod that explains the template-making process perfectly.
After tackling this project myself, I found a few ways to streamline the process and a few pitfalls you’ll want to avoid. Here is my breakdown of the gear and tips for a successful build.
The Gear List
While the original “trash can” method works great, I found that using pre-cut sheets can save a lot of prep time.
Category |
Item |
Notes |
The Plastic |
1/16″ ABS or Polycarbonate Sheet (12″x16″) |
Pro Tip: Polycarbonate is virtually shatterproof, while ABS is easier to heat-mold and comes in black. |
Alternative |
18-20 Gallon Plastic Tote |
Pick this up at a local hardware store. Look for “High-Density Polyethylene” (HDPE) for the best flexibility. |
Mounting |
Industrial Strength VELCRO (Black) |
Use the 2″ wide strips. It’s “no-drill” and allows you to remove the screen for technical trail sections. |
Cutting |
Heavy Duty Utility Knife / Razor |
You’ll want extra blades. Remember the “Hot Blade” trick for the cleanest cuts! |
Molding |
Variable Temp Heat Gun |
A hair dryer usually isn’t hot enough. A dedicated heat gun is essential for making those curves stay put. |
Tips From Trial and Error
I learned a few things the hard way during this build. Follow these tips to get a “factory” look instead of a “backyard” look:
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The “Hot Blade” Shortcut: Heat up your razor blade with the heat gun before you cut. It makes the blade glide through the plastic, preventing jagged edges and hand fatigue.
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Mark Your Bends: When you make your paper template, don’t just mark the outer shape. Mark the bend angles on the template so you know exactly where to apply heat to the plastic later.
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Heat: Using a heat gun isn’t strictly “required,” but it is highly recommended. If you try to force a bend in this plastic while it’s cold, it will break. Ask me how I know! Take your time if you choose not to use a heat source.
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The Sheet Advantage: If you go with the 12″ x 16″ sheets, you skip the struggle of trying to cut a flat piece out of a round trash can. It’s much easier to manage on a flat workbench.
How to Build It
The video below provides a fantastic step-by-step guide on creating your template and getting the fitment just right for your specific bike.
Final Thoughts
This is one of those mods that costs almost nothing but makes a massive difference on a 200-mile day. It’s tough, replaceable, and surprisingly effective. If you’ve been looking for a way to cut the wind without spending $150 on a name-brand screen, this is your weekend project.
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