If it's acrylic, it will be easier, but you can still achieve this pretty easily if it's polycarbonate. The fine tooth jigsaw will work. Go slow, use tape and make sure the rest of the shield is secure from vibrating excessively. Flame polishing is a cool effect for sure, but most likely the rest of your shield is not flame polished. I would do the fine grit sanding, or even the back side of your dish sponge. This should match the rest of the shield pretty well.

 

+1 on the blue tape, I just use a flush cut bit on my dremel, then a palm sander for the edge working down to 1000 grit, gives me a nice smooth and clear edge,

 

On mine I cut some off the bottom and did not have to mess with the top at all I dropped it about an inch
Just cut the notches about I inch deeper and be sure to cut some off the bottom to keep it from hitting anything in fairing

 

I have cut several windshields - just used grinder for the cuting and grinding to the tamplet and then hand Sandpapering the edges.

 

Do you happen to have a picture pf those adapter. I work on a sheet metal shop. Mimicking them shouldnt be hard if i have an idea.

None the less yall were a big help. Im gonna bring it in, and get started tomorrow

 

I used them on the inside of the windshield brackets, easier to pull the windshield out when sliding into the bushings, anyway this is a rough sketch of what they look like...i don't have access to alot of fabricating tools but I would have rounded the ends to match the curve of the frame.

Let us know how they turn out...