Let's talk about cutting down a stock windshield

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Nov 9, 2014 | 10:22 PM

#21

Retrop

Outstanding HDF Member

Joined: Nov 2008

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Quote:

Originally Posted by Bingee

There are numerous places on the net and youtube that can show you how to do this. I've done it myself and the results were great...as long as you make a good cardboard template, tape the entire shield to prevent scratches, use a very fine tooth jig saw blade and go very very slow. Keep the cut cool. And sand or polish the cut edge.

I have to echo what the poster above said. I have made a couple of windscreens from scratch and had excellent results cutting both of them. I covered my work bench with carpet to keep from scratching the plastic. I made a good template out of poster board and taped it to the sheet of Lexan. Next I outlined the template with a fine pointed laundry marker (black) so I could easily see the cut line.

It is very important to use a small toothed blade in your sabre saw. When I finished the cutting I used 600 grit wet/dry sandpaper to finish up the edges. It really looked like a store bought windscreen both times.
I purchased the Lexan in a pretty good sized sheet from Lowes, back in the glass department for about $30.00. It took about an hour to cut the new shield once the prep work was done. If you are a patient person, this is easily attainable.

Nov 10, 2014 | 05:49 AM

#22

katobird

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Joined: Dec 2006

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From: General Sherman's Christmas Location 1864

^^^ What he said^^^^ My stock shield was getting old, Instead of buying something that may not be the right one. I did the same thing, Lexan made my own. Taped it off, jigsaw with a semi coarse blade, not to overheat. sanded it and it worked out perfect.