Trim a Windshield
This started out on a whim, painting a long unused windshield, black. While there were those who appreciated the novelty of a painted windshield on a cruiser, some suggested I shorten it.
Since clear plastic is even harder to photograph than chrome, having a black painted bug catcher to cut seemed like a good opportunity for a how-to.
I’ve shortened fork mounted Memphis Shades® windshields before. This was bar mounted.
Note! I have never modified a coated/laminated windshield such as Honda OEM.
Begin by making a pattern of the windshield. I like to use heavy brown paper. Laying the paper flat against the front of the plastic crease it around the edge and tape it on the back. I used the mounting hardware to “index’” pattern so that I could remove it then return it to the original position.
Once the paper is secured, run the edge of a pencil around the edge of the plastic to trace the pattern. Remove and cut away the portion of the paper pattern where the top of the windshield is.
Alt: Use an Xacto® knife to cut away the top portion of the paper while it is still taped to the windshield.
Determine the shape desired and how much the shield will be shortened and trim the top of the pattern accordingly.
The photo shows a pattern traced on the black windshield and cut in half to give an idea of where we are going with this. The white mark is 2" below the top edge.
Mask the area of the windshield where the cut will be made with duct tape. Use the cheap stuff, it’s only to transfer the pattern and keep the plastic from being scratched during cutting.
Lay the pattern back on the plastic and trace the top edge onto the duct tape.
The cut will be made with a saber saw and the finest hacksaw blade you can get your hands on, a new one. Cut right to left, slowly (southpaws, reverse), saw on the front of the plastic.
Once the cut is made rub the edge with a rag or gloved hand to remove excess plastic.
The edge can be dressed with a file or sander. I like the Mouse.
Some also wipe the edge with acetone to make it clear.
Measure twice, cut once.
“I cut it three times and its still too short.”
I made the cut with the shield mounted on the handlebars and shoved it back during the process. That caused me to cut a dip in the top. I sanded it out, and then decided to make the shape rounder.
The second time I hand held it and got a smoother cut. Small imperfections can be sanded out.
