I just bought an OEM windshield for my 05 Heritage. I had previously cut down my original one so I could see over it. Although this one said it was 19", it was measured from the headlight cutout to the top of the shield. It seems they made the headlight cutout bigger, so I needed to cut this one down 2" as well. I used the same method. saber saw and a sanding block and file. My work was fine but I noticed what appears to be a delamination of some sort. Maybe from flexing it while cutting? I thought maybe it was a protective film that I had not removed. But when I tested an area under one of the metal brackets, no film. Its on the surface, because I can feel the bubbles. Maybe it will go away in the heat of day like window tint. Any comments folks?

 

Had a good scratch on RK windshield and went after it with Novus. Actually wore through a layer that was applied to Lexan. So, yes, there is a layer of ? on Lexan. Often thought the best way to cut down a windshield is with a router and home made jig but have not done it yet.

 

Any cutting of a windshield, I just take it to the local window shop.
$10 and they do the work!

 

I had that problem when I used tape to protect while cutting. The tape pulled off some of the coating when I removed it. The next shield I cut, I applied the soft Velcro to the bottom of the saber saw to protect the shield.

 

SamStone - That may have been my problem. I used a film used for protecting surfaces in construction that I applied to one side and wrapped over the edge while cutting. That would explain why it is happening on both sides. It seems to have mostly "rebonded". Certainly not enough issue to buy another one. Gonna get chipped and bugged up anyway. The router idea is good, but too much time would be spent making the jig. It cut nicely with the saber saw and was easy enough to smooth out with a sanding block. Thanks guys.