Cutting down a windshield???

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Nov 9, 2007 | 10:03 PM

itileman

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Outstanding HDF Member

Joined: May 2007

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From: Billings, MT

Cutting down a windshield???

Have the saw, sandpaperand tape ready to go. Question is, what's the best shape to use? I'm taking off about 2" off the top of a 19" HD standard quick detach shield. Best to cut straight across the top or contour & shape to the original structure? Any help would be greatly appreciated. I've been reading the posts as to how it's done, just wondering what's the best cut to make.

Nov 10, 2007 | 07:33 AM

Road_Clam

Road Captain

Joined: Nov 2006

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From: SE New Hampshire

RE: Cutting down a windshield???

Quote:

ORIGINAL: itileman

Have the saw, sandpaperand tape ready to go. Question is, what's the best shape to use? I'm taking off about 2" off the top of a 19" HD standard quick detach shield. Best to cut straight across the top or contour & shape to the original structure? Any help would be greatly appreciated. I've been reading the posts as to how it's done, just wondering what's the best cut to make.

I basically created a template of the original contour. The problem is as you remove height, you encounter added width. To overcome this I simply added a more gradual radius at the corners to compensate for the added width. I removed about 4" off my "King Size" WS. I like it much better, and it is still functional, and looks way better. I used an electric palm sander to remove the rough cut marks. I had to do a TON of sanding to get a clean line across the top.

Nov 10, 2007 | 02:44 PM

face

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RE: Cutting down a windshield???

i cut the bottom edge off my ultra's windshield this maintains the top edge, just make acardboard stencil of the factory bottom edge which is hidden behind the fairing also use alot off masking tape on the shield so as to stop any scratchesm from appearing

Nov 10, 2007 | 03:54 PM

itileman

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Joined: May 2007

Posts: 2,561

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From: Billings, MT

RE: Cutting down a windshield???

Thanks for the info. I'm a contractor, so I have no shortage of sanders. Will probably have to go the contour route - cutting off the bottom won't work with the quick detach, I'd have to move all the framing.
My belt sander does a good job of shaping, router might work too. Will post results when it's done (if I still have some fingers left to type with).