Jig sawed Windshield
Jig sawed Windshield
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!
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!
Last edited by Bobby9621; Mar 13, 2012 at 12:55 PM. Reason: Updated Pictures
Outstanding HDF Member
Joined: Sep 2010
Posts: 2,357
Likes: 8
From: Pa
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.
Cruiser
Joined: Jul 2011
Posts: 136
Likes: 1
From: Pensacola, Florida
Trending Topics
Outstanding HDF Member
Joined: Jul 2008
Posts: 2,111
Likes: 8
From: NW Arkansas
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Elite HDF Member
Joined: Sep 2008
Posts: 4,440
Likes: 148
From: Northwest
Here's the thread of how I did mine back in early '09.
https://www.hdforums.com/forum/dyna-...ight-done.html
