Cutting a windshield?

[Tripps]

I picked up am extra windshield for my Touring, I'm thinking of cutting about 5" or so off the top, so I can see over it. I can't be the first, I wondered how others have cut them. My tentative plan is to use a carbide router bit, I figure I can trace and cut a piece of 1/4" plywood or underlayment to the top profile of the windshield, then clamp it lower on the windshield to use as an edge guide to give me the correct profile.

 

[bonecarver]

I traced the contour from a second windshield,cut it out with a fine tooth jig saw, and then sanded the edge with a palm sander to round it over. Can not tell it from a factory windshield.

 

[Tripps]

I imagine anyone who could carve bones like your avatar pic would find a windshield easy meat.

 

[TRIIICK]

Trim a motorcycle windshield. - YouTube



FYI i cut vinyl all the time using a dremel not a good idea for smooth clean cuts. Unless you have a real steady hand and the right bit, i would stick with the saber/ jig saw .

 

[rainman]

Lets see pix when you get done

 

[Macrider]

windshield

Tripps, I did mine.
Use a fine toothed jigsaw blade.
First mark the windshield where you want to cut it.
Now make another mark about an inch or 2 above that.
Thats your rough cut.
Now use the factory top edge of the piece you cut as a template for your final cut.
Use masking tape on both sides.
It will still look rough so it will need some sanding of the edge to finish.
I used a palm sander to reduce some of the bumpy parts, then hand sanded with fine paper on a block of wood.

 

[DRMD421]

I did mine too. I wouldn't take that much off on the first pass, especially if you've never done it before. Cover the shields liberally with masking tape as Macrider said. Mark about 2" down and cut that with a fine tooth jig saw, taking your time. Then pull the tape off, sand it smooth on the edges and see how you like it. Drive it on the highway and see if that's enough before you take any more off of it. Now that you have confidence in doing it you can take more off as you wish. If you take off too much, wind will hit you just on the top of the head and will make a great big difference in helmet states because it will wear your neck out.

 

[Tripps]

Thanks. Yes, I recall someone saying they cut one with a dremel, but that definitely didn't seem the optimal way to me. I have both a router and a jigsaw, I may try the router higher with a practice cut and see how it works. May melt plastic from the speed, but if not it may give a smoother edge than a jigsaw, I'll report back.

 

[ewswartze]

The router will work just fine if you first rough cut the windshield to within 1/2 of the router bit diameter from the finished size. IE.... the router bit should be thought of as the finishing tool and not the cutting tool and that will minimize the heat. This method will still require some minimal sanding for a final touch but that will be nominal compared to the level of sanding required if you only cut with a jig saw. Another good tip is to cut on the outside of the arc of the windshield (the forward facing surface). Both methods work fine just a bit easier if you have the router and a jig. jm2cw

 

[Tripps]

The router will work just fine if you first rough cut the windshield to within 1/2 of the router bit diameter from the finished size. IE.... the router bit should be thought of as the finishing tool and not the cutting tool and that will minimize the heat. This method will still require some minimal sanding for a final touch but that will be nominal compared to the level of sanding required if you only cut with a jig saw. Another good tip is to cut on the outside of the arc of the windshield (the forward facing surface). Both methods work fine just a bit easier if you have the router and a jig. jm2cw

That sounds like a plan!