Windshield Help

[wildthang1949]

Good morning to all. My windshield is about 2-3 inches too tall, and I was wondering if it can be cut or sawed off without ruining it. Has anyone tried this, or maybe taken it to a glass shop to get er done?

[Joe Hummer]

I found a couple of articles on it by searching Google. 

here is a video...

How We Cut Down a Bike Windshield	powered by Aeva

and an article...

http://www.motorcyclecruiser.com/tech/remove_windshield/index.html

A trick for getting the edge nice and clear...which I learned from a guy who worked with plexi...is to use a torch to "melt" the edges.  Trust me...this is a tricky at best adventure but once you learn the technique, it make a super clean edge.  The main things to remember is to keep the flame moving and not to get heat on the flat surfaces.  Practice on the piece you cut off to get your technique down.  I would sand down the edge before flaming it...get it to a good finish and the flame will take out the rest. 

Joe

[Farther]

I cut my Hondaline windshield four inches following the instructions here on the forum and here:  http://www.motorcyclecruiser.com/tech/remove_windshield/index.html .  Turned out better than I had anticipated. 

[Cattman]

IF you use a jig saw, get a fine blade and run it at full out speed.  Slow speed and a medium blade cracked mine.

[fudgie]

Took my HD shield in to my local glass place and he cut it for $5.

[DFragn]

If you need 2" use a fine tooth jig saw then finish the remaining .5" with a belt sander. Then wet sand [800 grit wet type paper] by hand to clean up and round off the edge. Use painters tape to protect the screen from the saws foot plate.

You can contour easier with a belt sander then an orbital.

[ricoman]

It can be a pain but worth the result.
Start by taking a stiff peice of cardboard or heavy poster board and tape it to the outside of your windshield so it is higher and wider than the shield. Scribe the top radius shape of the shield onto the paper with a marker and come down the sides a bit..
Remove it from the windsheild and place it back on so the shield with the top of the radius on the paper where you want the top of the shield to be after it is cut. Trace the line you drew on the paper onto the windshield with the marker. Put masking tape (I used the blue stuff) along both sides of the cutting line you made on the windshield. Too wide is good.
You can use a jig saw but you will need to go very slowly or, as you cut, the heat generated by the blade will cause the cut windshield to melt/fuse together behind where you are cutting. This is a pita!
At the end of the cut (last 4 in. or so) be sure to hold both pieces until you finish the cut.
The edge can be smoothed pretty well with a hand grinder (air or electric). Final finishing can be done as was noted in previous posts. I have not used a torch as I do not want to push my luck!
Our local dealer uses a cutting bit in a hand router and does the entire cut in about 5 min. or less-he has done hundreds though. The jigsaw method has worked well for me twice.
Don't be afraid of it. (there are always used windshields in the classifieds!)

[Puffs Daddy]

Took my HD shield in to my local glass place and he cut it for $5.

A very smart approach.

[sheets]

Ditto "Ricoman".  Took 4" off mine a number of years ago.  The new top edge curve was the same as the oem.  The shield material is very soft.  Used a coarse wood rasp to clean up the rough chunky edge.  Then a regular file.  Then the sander.  About a half-hour job to make the cut.  Then time required to clean up the edge to suit (hour +/-).  Ymmv,   

[glenh]

Just take it to a glass place, they are very reasonable, will do it right and will save you a pain in the but doing it yourself.

[Gangman036]

I liked your solution fugie !!

[hillbilly]

I used a 5" grinder with a diamond blade, cut a little proud of the line dressed up with belt sander. Didn't remove from bike.

[Tundra]

Took 6" off, did not remove. Cover bike well to protect from shavings.
  I found you have much better suport when mounted. Extra set of hands helps stabilize the windshield while cutting. Less vibration, better cut, lessen the chance of cracking. Fine tooth blade, high speed, slow feed. This is very easy. The wind protection is actually very close to the same. I look over instead of through (which I prefer) and it just plain looks better. (many compliments)