The sun cap on the DFXL worked out pretty well. So I thought I’d build one for the WAW. I like the shape of the DF’s so I started with that. It was easier to mount on the WAW than on the DF since the WAW provides very nice clamps on the inside sides of the manhole cover. Here are some photos:

I’ll need to do some testing to make sure that it provides the shade and cooling without hurting the performance too much.

Construction of the Sun Cap

I’ve been asked to show a little bit about the construction of this sun cap. It’s been a while and I no longer own the WAW but here’s what I remember.

It started with the DF Sun Cap…Intercitybike was showing prototypes of the Sun Cap (or whatever they called it at the time). I liked the idea. Elsewhere, I referred to it as a Shade Cap. The ICB product wasn’t available to buy yet and since I had already made a mold of the DF hood, I just used my mold to make my own version for the DF. You can read more about it here…

The WAW didn’t have such an accessory so I decided to adapt my version of the DF Sun Cap for the WAW. For the WAW version I used the DF hood mold to produce the sun cap. It was the perfect shape and size. All I had to do was figure out how to mount it.

Here’s the finished cap. Notice the clear Lexan mounting posts. The tops of the posts are screwed to the hood with countersunk M4 screws and locknuts. The bottoms of the posts slide into the existing stock WAW windscreen clamps. Not shown is how the rear of the hood is held down. I believe that I had epoxied a hook or ring of some sort to the inside, rear of the cap. Attached to that ring was a bungee with a plastic hook that was attached to the rear lip of the stock cockpit cover. To prevent any paint scratches, I placed a strip of adhesive backed foam to the underside of the cap where the it rested on the body.

Ok… Here are some photos taken during the process of building the sun cap.

I popped out a copy of the DF Sun Cap from my mold and taped in place on the WAW. It’s essentially identical to the factory DF Sun Cap.

Here are the posts in position before being drilled. They are cut from a flat piece of 1/8″ Lexan (still in the white protective covering). Notice that there are some curves put into the posts with the help of a heat gun. The curve at the top of the posts was introduced to fit into the curves of the sun cap. Then a slight twist was put into the posts so that they were pointing into the wind and conforming to the sides of the cockpit cover. I intentionally left them a bit long so that I could raise and lower the cap to the position I liked best.

With the rear bungee attached to the cockpit cover (not shown), the Sun Cap stays attached to the cockpit cover as it is opened. The makes it more convenient to enter and exit the WAW compared to the DF with its Sun CaP.