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.
For comparison an un-modded Burgman
Any ideas on how to make the door or "side wind deflectors"?