Lowers (Updated March 2008):
It didn't take long to realize that the stock lowers were not fully effective in cutting all the wind down around the windshield. Being one for doing things myself whenever I can, I decided to make my own. I ended up making two sets, one with Lexan (Polycarbonate) material which look similar to the stock ones but larger and one from Acrylic (Plexiglass) which are larger yet and fill all the gaps but don't look as good in my opinion. One note is that Lexan is definitely easier to work with and does not melt like Acrylic when you cut it with a jig saw and is very slightly shaded which looks better. The reason for the two materials is that I bought them at different places. Lowes only has the Acrylic but I got the Lexan at a plastic store. I didn't think there would be such a difference in workability of the materials. Total price for both was around $25 and I still have enough left for another set.
Started with a card board template.
Used a jig saw to cut both pieces together (3/16" Lexan). Trimmed the edges on the bench grinder and filed the final edges by hand.
Trial fit but I didn't like the look.
I trimmed the tops off for a cleaner, less bulky look.
After testing these out, there still was a draft coming through the gap between the top of the lowers and bottom of windshield but directed at my knees, so no real bother. Just for grins, I decided to make another set and try to close the gap. I used the same design but extended the top around the turn signal.
These are the three sets with stock on the right, obviously.
These tested out very well with hardly any air blasts hitting me. I still don't like the looks of these but they can be my "cold weather" set for the winter.
Update March 2008:
I got some patterns of the Vulcan Riders Forum which were larger and I thought I'd try them just to see what the difference would be using these much larger lowers.
They kinda look like angel wings and I'm not sure I like them but for $15 I thought I'd at least try them. Well, they actually work very well. The wind is cut down substantially around the face and chest and only the legs are getting any kind of breeze.