Got the wife 06 Sportster 1200.
She has the standard height windsheild on the bike now, put it's like 1.5 inches to high for her,
we tried the low profile windshield, but that's too low.
Has anyone ever cut down a windshield and if so how do you go about it without screwing things
up, or are we just better off leaving things alone.

Thxs
Dan

 

use a compass (what u use to draw circles) use a grease pencil in the pencil side. space it the distance you want to cut off. the stationary side place along the top edge of the windshield and mark the line you want to cut. On the remaining side of the windshiled place enough masking tape (2") and wide enough to protect the windshield from scratches. With a variable speed jig saw using a metal fine tooth cutting blade, follow the line you marked at a slow speed. finish off with 400 wet and dry sand paper using water and a small amount of dish liquid in the water sand the edge to smooth off and round over. finish up using 600 wet and dry paper. Then use some polish to polish the edge off.

 

I think regardless of what you do, it's going to look like you cut it. Leave it be.

 

What Sleepneagle suggested is the way to go. To get a perfect edge sand it till smooth and straight with the 400 Wet or Dry wrapped around a small block of wood to keep the edge flat.

Once it is nice and smooth flame the edge with a propane torch lightly to glaze/melt the sanded edge. Try this 1st on a scrap piece of the windsheild material for practice. If the windsheild is lexan once you flame it the edge will be perfectly glassey. Works for scuffs and scratches as well.

 

nine, I've always had people that want me to cut their windshilds down, because it doesn't look like a hack job. There are valid reasons to trim one. Opinions are like **** Holes, Everyone has one!

 

Thanks for the replies.
I have an old windsheild that came of a rice grinder, I'll play around with that to see how it turns
out.

 

I just don't think someone who's never done it before, particularly someone who is particular enough about the bike to think the small is too small and the big is just a wee bit too big, is going to cut a windshield for the first time, and do it to his (or her) satisfaction.

My brother recently redrilled the mounting holes between the removable brackets and the windshield to lower his without cutting the windscreen. It's another option.

 

I cut mine, no problems at all.

I didn't do all the fancy stuff...

I used a piece of string tied to the center bolt to make the arc.
Lots of tape, dremel with side-cutter and router end after jigsaw shook too much. Next time, I will put a piece of rubber or something on the tip so the cutting bit can't pull out.

Orbital sander with 60 grit to shape, then 200 grit paper to remove grooves in the edge.

I practiced cutting high, as i was taking 3" off. I still cut high of my line and used the sander to take it smooth. It would have been perfect, but I got distracted and made a small scratch. It polished mostly out with the Novus 3 step.

The original edge was frosted, my new edge looks exactly the same.

It's easy to do the cutting and polishing. What took me a long time was getting an arc I was happy with. The arc took at least an hour as I tried paper, compass, freehand, garbagecan lid, string, etc...

It's so worth it, I can't begin to tell you. If you have a poorly fitting shield, this can make a world of difference.

 

I used a standard band saw to cut access off and get the cut within .25 in of my line. I then used a file to get it closer and once to my grease pencil mark, i used thin grit sand paper to smooth the edges and get everything even.
it takes some time and patience, but the end result is a windshield custom fit for your height.

Also check the yellow pages, there are glass and plexiglass places that will custom cut sheets of plexiglass for you.

 

I took one to a local auto glass shop had it cut down. You couldn't tell their cut from the factory cut. They charged me 20 bucks.