Cut down stock windshield
Grand HDF Member
Joined: May 2006
Posts: 4,363
Likes: 3,622
From: SE NC
Well...I've seen it done this way, didn't booger it up to much.
Measure where you want to cut, put masking tape (or something similar) on both sides of the windscreen, then use a very fine saw blade (jig or hack saw) and start cutting, make sure your windscreen is very stable/secure. You can smooth out the edges with some very fine emry cloth/sandpaper and polish it if need be with some very fine buffing compound and maybe even toothpaste.
I've seen a dremmel tool used once, but it went so fast it melted the plastic along the way and was harder to clean up, maybe some one knows the techinque, but I would do the saw thing.
Don't hold me to it, but it worked at that particular time.
Measure where you want to cut, put masking tape (or something similar) on both sides of the windscreen, then use a very fine saw blade (jig or hack saw) and start cutting, make sure your windscreen is very stable/secure. You can smooth out the edges with some very fine emry cloth/sandpaper and polish it if need be with some very fine buffing compound and maybe even toothpaste.
I've seen a dremmel tool used once, but it went so fast it melted the plastic along the way and was harder to clean up, maybe some one knows the techinque, but I would do the saw thing.
Don't hold me to it, but it worked at that particular time.
Advanced
Joined: May 2008
Posts: 53
Likes: 0
From: maryland
I have done quite a few with a fine tooth blade,16/ 18 tooth, on a band saw with excellent results.I am sure it would work well with hand held jig saw provided you have a steady hand and good work surface.I used masking tape to cover the windshield surface to protect it from scratches and draw my cut line,then finish it off with a sanding block and some 80 grit paper.
Tourer
Joined: Jul 2009
Posts: 269
Likes: 1
From: Madison WI
rotozip works great too.
helped a friend cut his, taped it all up, drew the line, etc...he has a steady hand, and the cut turned out great. block sanded with some 400, and you couldn't tell it was cut down.
helped a friend cut his, taped it all up, drew the line, etc...he has a steady hand, and the cut turned out great. block sanded with some 400, and you couldn't tell it was cut down.
Cruiser
Joined: Mar 2009
Posts: 170
Likes: 0
From: Wausau Wis
I cut one from the bottom with jig saw. a little more intricate cut but it hides the cut in the fairing. Then i wasnt worried about the edge.I was also hidding some holes someone had drilled to mount something.
Road Captain
Joined: Mar 2009
Posts: 702
Likes: 1
From: U.S.S.A.
If you're just taking a few inches off, don't cut from the top -- cut from the bottom! I did this a few times and it's easy and leaves you with the same smooth professional edge with no risk of screw up that's visible.
I traced the shape of the lower shield onto poster board, then cut that out as a template. Then I masked the bottom of the shield with painter's tape and with the posterboard template, traced the bottom contour onto the taped stock screen, exactly .75" above the bottom. Five minutes under a jigsaw with a fine-tooth blade, and the job was done. No need to finish the edges (they're all hidden), no polishing and a totally factory look.
Unless you're lopping 6 inches off the shield (the taper would make the shield too narrow at the bottom), I recommend cutting your shield off at the bottom. Super-easy. For me, 11.25" seems to be the perfect height to look over the shield without getting too much buffeting. YMMV.
I traced the shape of the lower shield onto poster board, then cut that out as a template. Then I masked the bottom of the shield with painter's tape and with the posterboard template, traced the bottom contour onto the taped stock screen, exactly .75" above the bottom. Five minutes under a jigsaw with a fine-tooth blade, and the job was done. No need to finish the edges (they're all hidden), no polishing and a totally factory look.
Unless you're lopping 6 inches off the shield (the taper would make the shield too narrow at the bottom), I recommend cutting your shield off at the bottom. Super-easy. For me, 11.25" seems to be the perfect height to look over the shield without getting too much buffeting. YMMV.
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