Pics first:
Cost: $4 for 1'x3' of 1/4" metal mesh from the hardware store, 30 minutes of getting pricked by pointy metal.
Instructions:
1) cut a square of mesh of the right size.
2) Unscrew the 2 screws on the bottom of the headlight, place the mesh over the screw hole, screw the screw back in to hold the mesh in place.
3) Do the same at the mounting holes that secure the headlight to the bike. If you're using 1/4" mesh, you will need to cut a section out to make enough space for the mounting screws.
4) Cut the mesh down the center line from the top of the mesh to where you want the apex of the guard's curve to be.
5) Fold the top sections over each other so the top corners of the mesh come together. You will need to cut away some excess mesh in order to bring the corners together, but leave some mesh to overlap.
6)Secure the 2 top corners under the top middle headlight screw. I didn't cut a big enough square so I had to weave another small section of mesh onto the first section in order for it to reach; no big deal.
7) This is where the design gets its rigidity: interlace the inside edges of the top sections into the opposing section. Try pressing the mesh from the front with your hand; if you did it right, you will feel the mesh become more rigid as more force is applied.
