looking into all options on replacing my windshield on my 89 baja sport 250. i have seen people do this as simple as taking a piece of plexi glass and cutting and bending it to match, my question is how hard is this to do? anyone tried it? the other option is a "race faring" out of fiberglass. or if you have a windshield for a 89 sport 250, 90 250 es, 91 on 270.... even if it is broken i would be intersted in it

I've made them as well as a few other items.
Lexan bends really well and is really hard to break.
With plexi, you really need to heat it in order to get a bend that wont eventually break. You can do that in an oven, about 300 degrees, or using a propane torch. Both can be cut and drilled with standard woodworking tools, just go slow to prevent melting. Plexi is cheaper and has more color selections.
You can get a finished edge by sanding then quickly heating with an acetylene torch. I've also used aluminum C channel to mount it or put a finished top edge.

do you have to heat the lexan to bend it also? i am worried about the near 90 degree bends on the sides

Plastic supply shops can bend your plastic for only a few bucks.

curbell plastics is hwere I used to get all my plastics. did A bunch on drag cars and I even used PETG on some and did the colors glass. Looked really retro on the race cars.

I've considered this but have never been able to come up with a good way to attach it to the boat. Do you guys have any good ideas?