Windshield cut to fit new headlight... done.
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Elite HDF Member
Joined: Sep 2008
Posts: 4,440
Likes: 148
From: Northwest
Windshield cut to fit new headlight... done.
Well got the windshield cut to fit the new headlight and such.
Here's my steps:
1). Loosened my headlight and rotated it forward, so that I could attach the windshield.
2). Applied blue painters tape - two layers worth - to cover area being cut and surrounding area to protect from scratches.
3). Rotated the headlight back up to barely touching the windshield, and marked the edges of the light assembly + 1/4". Then marked a straight line up the windshield.
4). Not shown, however I then removed the windshield and rotated the headlight back up, to find where the top of the headlight winds up. Made mental note of that (it was even with the top of my handlebar mount).
5). Checkng step 4, with the windshield in the full up position, recheck where the top of the headlight would be with the windshield all the way up. Turns out its even with the stock opening.
6). I removed the windshield, and made cuts approximately halfway up, and reinstalled the windshield to check for alignment and such.
7). Now is when I raided the kitchen and found a pot lid that was pretty darn close to the diameter of the new headlight.
8). Using the top of my handlebar mount, I made a TOP cut mark and then using said pot lid, I finished marking my cut lines on the tape.
9). Finished cutting and remounted the windshield for another fittment/alignment check, and made some small adjustments. Windshield is in full down position here.
10). Picture of the blade I used in my jigsaw to make the cuts.
11). Windshield edges all filed and sanded smooth. Windshield in full down position.
12). Windshield in full up position.
13). Windshield bag remounted, and assembly in full down position. Everything still fits!
Tools used:
Jigsaw with fine blade.
medium coarse flat file with rounded back.
150 grit sandpaper.
350 grit sandpaper.
blue painters tape.
Hope this helps anybody else thinking about doing this. Was really a piece of cake.
Here's my steps:
1). Loosened my headlight and rotated it forward, so that I could attach the windshield.
2). Applied blue painters tape - two layers worth - to cover area being cut and surrounding area to protect from scratches.
3). Rotated the headlight back up to barely touching the windshield, and marked the edges of the light assembly + 1/4". Then marked a straight line up the windshield.
4). Not shown, however I then removed the windshield and rotated the headlight back up, to find where the top of the headlight winds up. Made mental note of that (it was even with the top of my handlebar mount).
5). Checkng step 4, with the windshield in the full up position, recheck where the top of the headlight would be with the windshield all the way up. Turns out its even with the stock opening.
6). I removed the windshield, and made cuts approximately halfway up, and reinstalled the windshield to check for alignment and such.
7). Now is when I raided the kitchen and found a pot lid that was pretty darn close to the diameter of the new headlight.
8). Using the top of my handlebar mount, I made a TOP cut mark and then using said pot lid, I finished marking my cut lines on the tape.
9). Finished cutting and remounted the windshield for another fittment/alignment check, and made some small adjustments. Windshield is in full down position here.
10). Picture of the blade I used in my jigsaw to make the cuts.
11). Windshield edges all filed and sanded smooth. Windshield in full down position.
12). Windshield in full up position.
13). Windshield bag remounted, and assembly in full down position. Everything still fits!
Tools used:
Jigsaw with fine blade.
medium coarse flat file with rounded back.
150 grit sandpaper.
350 grit sandpaper.
blue painters tape.
Hope this helps anybody else thinking about doing this. Was really a piece of cake.
Tourer
Joined: Aug 2007
Posts: 329
Likes: 0
From: Stafford, KS
Nice write up, my step dad has the same w/s as you and it is to tall for him. I am gonna forward this to him so he can see what you have done and maybe try it for himself.
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Thread Starter
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Elite HDF Member
Joined: Sep 2008
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From: Northwest
Thanks for the thumbs up!
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Thread Starter
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Elite HDF Member
Joined: Sep 2008
Posts: 4,440
Likes: 148
From: Northwest
Wound up riding down to Lewiston and back.... stopped by Shumate and ate a dog and drank some coffee. Turns out I was the "guy" who came down from on top today......... crazy bastard... " 
.... have no idea what they're talking about ....
Only a windchill of +16degrees for 35 miles ....one way....
Had to do it though.... not riding was driving me nuts.
.... have no idea what they're talking about ....
Only a windchill of +16degrees for 35 miles ....one way....
Had to do it though.... not riding was driving me nuts.
Ultimate HDF Member
Joined: Dec 2008
Posts: 5,120
Likes: 17
From: Indiana
Nice. I was thinking about that just not today. How many layers of clothes did you put on. Maybe I'll next week when its in the 40s not the 30s. I bet it was nice and dry down in lewiston.