How do I trim my windshield.........

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Jul 8, 2010 | 11:32 AM

ginboy64

Thread Starter

Intermediate

Joined: Sep 2009

Posts: 35

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From: Arkansas

How do I trim my windshield.........

I am wanting to replace the stock headlight on my FatBoy Lo with a freight train headlight. I have a HD windshield on it and want to keep it there. I was told that I will have to trim the botom of the windshield to accomodate the new headlight. I've never cut anything like the windshield material and am looking for tips on this. I don't mind doing it myself........ just looking for some help. Thanks in advance for your help.

Jul 8, 2010 | 11:44 AM

07Fatty

Tourer

Joined: Jun 2007

Posts: 436

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From: Bartow, Fl.

tape it off mark it cut it with a jig saw or dremel

Jul 8, 2010 | 12:05 PM

Jackie Paper

Seasoned HDF Member

Joined: Mar 2010

Posts: 38,305

Likes: 6,325

From: Honah Lee

Cut

When you apply the masking tape for protection you might want to tape it to the bottom side of the saw and not the windshield. I have cut a few off and when the saw vibrated down on the poly carbonate it made the masking tape bond real tight in small spots. Most factory Harleys have a thin piece of tint film over the front and when I pulled the tape there were a few spots that pulled the tint off. Not sure but maybe if tint was not on reverse side it would have been OK on that side to put the tape on. I just put the protection on saw and I also have a shiny non stick blade that has 20 teeth. Lot of wood blades are 6,8 or 12 which is a little coarse. I push slow and close to line so as not to chip and then I take a 1" round belt sander wheel and go over the cut to blind just like the outside following up with a folded piece of worn-out 360 by hand. Can not tell it from the factory cuts. Note I lay it out with a set of dividers letting one leg drop over the edge and say if I want to open it up 1/2 inch I run the sharp edge in 1/2" and scratch my line staying away from corner. I template the corners on a piece of cardboard and cut it out and use it to mark corners Then just blend corners to the original radius. I lay the windshield on a big old blanket for support and leave cut edge out off end of bench. My blade cuts thru it like hot butter right to my marked edge. Been doing wood work for 40+ years so if you have never cut poly carb, get yourself a scrap piece of 1/4 plex-glass may not be a bad idea if you are not familiar with your saw. I would hate to ruin a Harley Windshield. I have see some cheap generics on e-bay but Harley dealer thinks the are made of gold--at least silver

Last edited by Jackie Paper; Jul 9, 2010 at 11:42 AM.