I didn't like the windshield that was on my Springer so I thought I'd try cutting it down. I heard all kinds of stories about how they crack and it takes special tools to do it. Well I mask the entire sheild then drew my lines on it and went to the band saw. No problem. It cut like any other plexiglass. I hand sanded the edge and need to do a little more before it looks factory. Anyway it's not all that difficult.
No that's not a crack at the top it's a finger print.
[IMG]local://upfiles/47469/3A7BFD9869BE4C6DBBFD4C41FD474EB1.jpg[/IMG]

 

You did good.

 

Nice job. I too would be a bit afraid of cutting a windshield. You use a fine blade to avoid chipping and splintering?

 

well done

 

No, this was a 7 tooth I beleive. For wood cutting. I just made sure the windsheild was flat at the blade while cutting. I tried sanding it with an upright belt sander. It left the edge course and wanted to melt it if I didn't keep moving. The hand sanding is the best. The finer the grit the more it gets that dark blue line that a stock cut has.

 

You can use a jigsaw with a wood blade as well.
I used a Dremel with a side cutting blade.
Sanding I used 200 grit on an orbital and got an exact match to the factory.

Looks like you did a great job. Hardest part for me was figuring out a line I liked... well that and getting the courage to cut it.

 

Not bad, not bad at all, Nice.

Mimo.

 

I've trimmed 3 windshields to fit me and my bikes using a Sears sabersaw equipped with a "fine scrolling" saw blade. The sides of the blade have been ground flat and have no teeth protruding. It's made by Lenox and picked it up at the local hardware store. Adjust your saws speed so that you don't cause melt or burn.

 

since I didn't have a band saw or a jigsaw available, I took it to a local glass shop... they cut and polished it for $20.00.

 

I cut my 2 previous ones with a saber/jig saw. The one I just cut on my new bike, I used one of those "Roto-Zip" tools. No problems with any of them.