Cutting windshields down
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
RE: Cutting windshields down
I've cut down two windshields for my RK, the stock WS and a HD adjustable WS purchased later, both about 1 3/4". I also have a "shorty" that's 4" lower than stock, but I haven't violated it yet. The steps I used was first to cut a piece of cardboard and tape it to the windshield to determine the best height. I want to look just over the windshield, but not much, as lowering it too much will cause helmet buffeting at higher speeds. To get the right and left sides of the cut the same, I picked one side of my cardboard cutout and flopped it, essentially providing a duplicate in the opposite direction. Some of engineers may have a better solution to get both sides even, but this worked for me.
Once the height was determined I marked where the cut was to be made and cut it with a scroll saw using motor oil as a lubricant. This will result in a rather coarse cut that needs to be smoothed. The first windshield I used a hand sanding block, first with coarse sandpaper and later with fine, and this will eventually smooth it down acceptably. This is hardest part of the job. On my second windshield a friend introduced me to a better method of smoothing the edge: the concrete garage floor. Odd as this sounds, it worked great--effective and much faster than sandpaper. Just hold it firmly and stroke it evenly until smooth.
One of the best accessories I've purchased for touring is the HD adjustable, and I even cut it down. I want it higher on the interstate and in rain, but lower in the mountains and at slower speeds.
I don't know about aftermarket windshields, but HD doesn't provide enough of a range to suit me, usually 3 or 4" between choices. To me it needs to be right on to be effective, and I think every person will have a different "sweet spot" for windshield height.
Once the height was determined I marked where the cut was to be made and cut it with a scroll saw using motor oil as a lubricant. This will result in a rather coarse cut that needs to be smoothed. The first windshield I used a hand sanding block, first with coarse sandpaper and later with fine, and this will eventually smooth it down acceptably. This is hardest part of the job. On my second windshield a friend introduced me to a better method of smoothing the edge: the concrete garage floor. Odd as this sounds, it worked great--effective and much faster than sandpaper. Just hold it firmly and stroke it evenly until smooth.
One of the best accessories I've purchased for touring is the HD adjustable, and I even cut it down. I want it higher on the interstate and in rain, but lower in the mountains and at slower speeds.
I don't know about aftermarket windshields, but HD doesn't provide enough of a range to suit me, usually 3 or 4" between choices. To me it needs to be right on to be effective, and I think every person will have a different "sweet spot" for windshield height.
Thread Starter
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Seasoned HDF Member
Joined: Sep 2005
Posts: 5,072
Likes: 104
From: Prescott, AZ
RE: Cutting windshields down
ORIGINAL: iclick
I've cut down two windshields for my RK, the stock WS and a HD adjustable WS purchased later, both about 1 3/4". I also have a "shorty" that's 4" lower than stock, but I haven't violated it yet. The steps I used was first to cut a piece of cardboard and tape it to the windshield to determine the best height. I want to look just over the windshield, but not much, as lowering it too much will cause helmet buffeting at higher speeds. To get the right and left sides of the cut the same, I picked one side of my cardboard cutout and flopped it, essentially providing a duplicate in the opposite direction. Some of engineers may have a better solution to get both sides even, but this worked for me.
Once the height was determined I marked where the cut was to be made and cut it with a scroll saw using motor oil as a lubricant. This will result in a rather coarse cut that needs to be smoothed. The first windshield I used a hand sanding block, first with coarse sandpaper and later with fine, and this will eventually smooth it down acceptably. This is hardest part of the job. On my second windshield a friend introduced me to a better method of smoothing the edge: the concrete garage floor. Odd as this sounds, it worked great--effective and much faster than sandpaper. Just hold it firmly and stroke it evenly until smooth.
One of the best accessories I've purchased for touring is the HD adjustable, and I even cut it down. I want it higher on the interstate and in rain, but lower in the mountains and at slower speeds.
I don't know about aftermarket windshields, but HD doesn't provide enough of a range to suit me, usually 3 or 4" between choices. To me it needs to be right on to be effective, and I think every person will have a different "sweet spot" for windshield height.
I've cut down two windshields for my RK, the stock WS and a HD adjustable WS purchased later, both about 1 3/4". I also have a "shorty" that's 4" lower than stock, but I haven't violated it yet. The steps I used was first to cut a piece of cardboard and tape it to the windshield to determine the best height. I want to look just over the windshield, but not much, as lowering it too much will cause helmet buffeting at higher speeds. To get the right and left sides of the cut the same, I picked one side of my cardboard cutout and flopped it, essentially providing a duplicate in the opposite direction. Some of engineers may have a better solution to get both sides even, but this worked for me.
Once the height was determined I marked where the cut was to be made and cut it with a scroll saw using motor oil as a lubricant. This will result in a rather coarse cut that needs to be smoothed. The first windshield I used a hand sanding block, first with coarse sandpaper and later with fine, and this will eventually smooth it down acceptably. This is hardest part of the job. On my second windshield a friend introduced me to a better method of smoothing the edge: the concrete garage floor. Odd as this sounds, it worked great--effective and much faster than sandpaper. Just hold it firmly and stroke it evenly until smooth.
One of the best accessories I've purchased for touring is the HD adjustable, and I even cut it down. I want it higher on the interstate and in rain, but lower in the mountains and at slower speeds.
I don't know about aftermarket windshields, but HD doesn't provide enough of a range to suit me, usually 3 or 4" between choices. To me it needs to be right on to be effective, and I think every person will have a different "sweet spot" for windshield height.
Some of the best advice in the world - lol - sorry just couldn't refuse
BTW - I am a fan of both the EG and now RG - However, your "Old Blue" bike is one of the best solo classice touring bikes I have seen - Great job...
Cruiser
Joined: Jun 2006
Posts: 216
Likes: 0
RE: Cutting windshields down
I brought mine to a glass shop. I knew the people at the shop and asked if they cut down harley windshields. Said yeah bring it on in. Cut it down to 9" from stock charged me $15, which I htought was pretty cheap. If you bring it to someone ask them how many they have done. btw 9" was to damn short!! should've gone with 10". Lesson htere is if your not sure of the length start on the long side!!
Road Master
Joined: Jul 2006
Posts: 762
Likes: 0
From:
RE: Cutting windshields down
I cut mine down on my Deuce. Used the Router/Zipper tool from Sears. Measured, drew line, taped up and cut......slowly! Then put clear coat along the edge. Been just fine for 2 years.
Ultimate HDF Member
Joined: Nov 2005
Posts: 5,256
Likes: 5
From: Concord, CA
RE: Cutting windshields down
Cut mine as well, but if I could have bought one for $30, I probably would have gone that route.
The mystery coating is not put on after the shield is cut. The lexan comes that way in a big sheet.
It will not peel.
The mystery coating is not put on after the shield is cut. The lexan comes that way in a big sheet.
It will not peel.
Road Master
Joined: Jul 2006
Posts: 762
Likes: 0
From:
RE: Cutting windshields down
Intermediate
Joined: Aug 2006
Posts: 33
Likes: 0
RE: Cutting windshields down
I've had three different fairings on my RK and never bought a premade windshield yet. I use tinted lexan from the local plastic company. I cut it on my bandsaw then sand the edge with progressively finer sandpaper until smooth. I've had great success and the shields average about $20 to make. Just make a cardboard template first to make sure you aren't making too short, then trace the outline on the lexan.
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Seasoned HDF Member
Joined: Sep 2005
Posts: 5,072
Likes: 104
From: Prescott, AZ
RE: Cutting windshields down
Cut the stock shield today, Actually, went pretty easy.... biggest thing, do this when the wife is at work... used out coffee table....... tapped windshield, laid towel down, used 2x4 held shield down flat.... after line was drawn, used hand held jig saw with proper blade, went very nice... left tape on... started with 60 then 80 then 100 then 120 then 180 paper (full sheet on a 2x4) got a very straight line,,, used smaller blocks for the rounded ends.... installed shield on bike... Now I will finish the edge and polish what is left...
Like I said before - I have two stock shields I got off Ebay at a very good price, wanted to try this, worked fine... for my height, I went with 12.5 inches, measured from the center of the center screw. This will allow me to see over and still creat a nice pocket for the wife on back....
My only wish - would be that it was a little tinted???? maybe on the next one...
Like I said before - I have two stock shields I got off Ebay at a very good price, wanted to try this, worked fine... for my height, I went with 12.5 inches, measured from the center of the center screw. This will allow me to see over and still creat a nice pocket for the wife on back....
My only wish - would be that it was a little tinted???? maybe on the next one...
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