Don, I have the lexan - but where did your velcro dots come from - or
what brand were they., Sources here are different and difficult at times.

Thanks,

John

On 12/4/2012 10:02 PM, Don Hanson wrote:
>     I didn't read the "thread" except for the subject so maybe this has been
> mentioned...
>
>     My Vanagon hasn't had problems with broken headlamps but if it did I
> would do what I did on one of my dirtbikes, a KTM that saw lots of rocks
> thrown up by other bikes ahead of me on fire roads and down in Baja.   It
> had a flat lens, like my E-code lights in the van, so this would work on
> the van also.   I had some 1/8" Lexan left over from a boat I was working
> on so I cut a piece to cover the headlamp.   You can easily work Lexan with
> home shop tools. You can cut it with a jig saw and smooth it with a
> sander....I have a band saw and a router I rounded over the edges with...
> I used some of those industrial strength stick-on velcro 'dots' to hold the
> lexan lens shield onto the outside of the headlamp...Removable for cleaning
> and  it never came off during riding or crashes.   That thickness of Lexan
> is supposed to be able to withstand a 22 long rifle bullet fired at it....I
> know it repelled the "roost" on some pretty wild motor excursions.   You
> could probably use 'smoke' Lexan if you wanted the 'blacked-out' custom
> look....The lens cover on my moto was smoke and I couldn't tell any
> difference in illumination  with it on or off the bike.  Lexan is neat
> stuff that I find many uses for in my van and boats.
>