Fabrication of a Convertible Roof System for Two-Wheeler

Two-wheelers represent a significant portion of personal transportation systems, particularly in densely populated urban regions of developing countries. Despite their advantages in terms of fuel efficiency, maneuverability, and cost-effectiveness, riders are continuously exposed to adverse environmental conditions such as rainfall, ultraviolet radiation, wind turbulence, and airborne dust particles. Prolonged exposure to these conditions can reduce rider comfort, impair visibility, and negatively affect overall driving safety. This study presents the design, structural analysis, and fabrication of a lightweight convertible roof system intended for integration with standard scooter platforms. The system is designed to provide protective coverage while maintaining vehicle stability, maneuverability, and aerodynamic efficiency. The structural frame is fabricated using Aluminium 6061-T6 square tubing, selected for its high strength-to-weight ratio, corrosion resistance, and weldability. The canopy surface consists of UV-resistant polycarbonate panels, providing transparency, impact resistance, and durability under outdoor environmental conditions. The design methodology incorporates ergonomic analysis, aerodynamic load estimation, structural stress calculations, and material selection criteria to ensure functional feasibility and rider safety. Particular emphasis was placed on passenger clearance, resulting in a raised rear roof configuration that ensures a minimum helmet clearance of 100 mm. Aerodynamic load calculations were performed using the standard drag equation to estimate wind forces acting on the canopy structure during vehicle operation. The developed prototype demonstrates improved protection against sunlight and rainfall while maintaining minimal impact on vehicle centre of gravity and handling characteristics. The proposed system offers a practical, economical, and structurally feasible solution for enhancing rider comfort and safety in urban commuting applications.