UPDATE: I finished the front end (except the door) out of .093 polycarbonate. Bending it wasn't easy as shown by the bubble on the windshield when I over did it ... will cut, and replace that section.
Note: The side rod will be part of the wind deflector frame. It will be a velcro on/off attachment made from the same Al. rod that is used in the frame. This will allow me to lane split and travel through canyons without getting blown over.
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For comparison an un-modded Burgman
Any ideas on how to make the door or "side wind deflectors"?