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I found this page a long time ago and saved a basic copy of the information for future reference. I have tried to locate it again but can't find it, so here is a repost of the information. I hope no one is offended with the repost of their original information. If you know the web site where this is from I would gladly give the credit or just link to their page. -c
Instructions
Lowers from these patters mount to the stock Nomad lowers bracket, using the stock screws.
It is recommend that you print the pattern and use it to create a pattern from cardboard. Remove your original lowers, and mount the cardboard pattern to the bike using the stock bracket and screws. Trim the cardboard pattern so that it clears your turn signals, crash bar, light bar, and windshield. Make sure you turn the front wheel left and right (up against the steering stops) to make sure the pattern clears the crash bars.
Once you have trimmed the pattern to fit, affix it to your plexiglass with double-sided carpet tape and cut out the lowers. For best results, cut out both lowers at the same time. Use double-sided tape or hot-melt glue to hold them together during the cutting operation.
You can make your lowers from Acrylic sheet (approx .180" thick), available from Home Depot and other home centers. Lexan, Plexiglass, and similar materials work fine. Some have even cut them from diamond plate aluminum so the material and thickness you choose is pretty much up to you.
You can cut your lowers using a gig saw or can also use a band saw, coping saw, or virtually any cutting tool. Take care not to overheat the material as you cut as it will tend to gum up and possibly affect your cut line. When you're finished cutting, you will want to deburr and slightly round over the edges. A file, and sand paper is likely best. Be careful with sandpaper, as it is very easy to scratch the front and back surfaces.
These lowers can be made for about $10 and 1/2 hour of time.
These lowers fit the 2006 Nomad and are made to mate closely to the bottom edge of the windshield in the lowest position.
Step 1: Bend the existing lowers brackets to 20 degrees so the lower will better follow the contour of the curve in the windshield. Take some 1" oak or other hardwood and rip one with the blade set on 20 degrees, the other just ripped square. Place the blocks and the mount in the vise as seen in pictures 1 & 2. Use a plastic mallet and bent the bracket until it contacted the bevel cut in the oak block.
Step 2: Print the PDF file and tape them together at the two lines. Measure the distance between the mounting holes to make sure they are spaced correctly, (3 15/16"). Adjust the two sheets to obtain the correct distance.
Step 3: Bolt both pieces of Plexiglass together and use double sided tape to affix the template. Cut them out on a band saw (or jig saw, or...) and sand the edges to smooth them out. Install them and enjoy your new custom lowers! See picture 3 & 4 to see how good they will look when you are finished. Well worth the couple hours work.
Click to Download 2006 Nomad Lowers Pattern
Image 1
Image 2
Image 3
Image 4
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