I never thought I would ever use a jigsaw on a bike…

I took the plunge on my detachable windshield. I have it set low, and wanted to trim the top to be proper height, since I was looking through it unless I sat straight up to see over. Trimmed 4 inches. HD 58346-06

Jigsaw, poster board, 3M Painters tape, fine tooth blade, two files, coarse and fine, and then sandpaper, 20 grit to 120 grit.
I first measured, then measured, and ummm measured again. I made my template from the poster board of the original size, the metal bracket bar makes a nice point of ref, and then cut off my desired size of 4 inches from the bottom of the template. I took the painters tape to both sides to prevent cracks. I took my template and marked to almost the middle, the high point of the template. Then moved the template over and marked to the high point again, then drew a straight line to finish. I put a sheet over the bike for protection. I cut from bottom right to left in one cut nice and slow while on the bike. I then filed the uneven points, then the entire edge from coarse to fine. Then sanded, and eventually wet sanded to 120 grit. I still need to do final sand, and verify all bumps or uneven edges are perfect.

I didn’t know if I would cry or have a crap eatin grin, just glad I didn’t have to buy another shield!

 

good job. i did this to a windshield. after filing the rough spots, i just wound up wet sanding the cut edge and it came out smooth as glass. 1st time i did it i ran the jig saw to fast and melted the cut edge back on. had to cut it twice.

 

looks good, i need to do the same, did you run the jiggsaw at full speed?

 

I have a dewalt variable speed jigsaw, ran it slow. Not too slow to snag, or too fast to miss the line.

 

Forgot to post the third pic...

 

Did the same a couple years ago when installing a fatboy headlight... after all was said and done, took a small propane torch and, for the lack of a better term.. flame sealed the edges.

 

Nice work!

 

Nice job. Did mine a couple years ago to fit my 7" fatboy headlight.

 

I need to cut mine out for a 7" light.

Anyone have any tips other than covering everything with tape and using a fine blade and steady hand?

and a decent jig saw which i dont have

 

Here's the thread of how I did mine back in early '09.

https://www.hdforums.com/forum/dyna-...ight-done.html