• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

  • In order to help others find info on a particular bike, be sure to put the year, make or model of bike that you are asking a question about, in the Topic Title. This will allow people to pass by posts they have no interest in.

Cutting down a windshield

Vmass

Vmass

Forum Sage
Past Site Supporter
The windshield on this bike is a bit too tall for me. Victory does (did) make a shorter version and if you can find it they are bringing $300-$500 bucks.

So, I was fortunate to find a brand new Victory shield the same height as mine for $80.00 bucks!

I have watched a couple videos on how to cut it down and I think I am good with what I watched. My unanswered question is what is the best blade to use? The saw that most used was a jig saw, which is good for stability considering the base of the saw.

What is the best jig saw blade to cut this shield? Thanks!



 
You use a fine-tooth blade ONLY.

Alternatively, use a spin saw with a drywall bit.

SLOW cutting is the only way to do this. Take your time. Pushing too fast makes the blade very hot very quickly. A hot blade will melt the plastic, and make your cuts irregular, as well

Once cut down, use a belt sander....gently....to smooth off any irregularities and round the edges. Use a fine grit (120 or higher number)

It is best to place wide maskiing tape across the surface and around the area to allow for the saw to move across tape only. Draw your intended cut line on the tape. This will keep the saw base off the surface and prevent damage to the surface while cutting and give you the pattern you want.

Another suggestion...remove the windshield from the bike and have it on some sort of raised support. This will help accuracy and prevent both errors and injury.
 
yes^^^ slow... power tools really tend to melt it. if you can cool with something, might help AND a handheld jigsaw will tend to vibrate the the windshield....BE Sure it is a "lexan" and not a Plexiglass which cracks very easily...plenty of info on this here's the top of the pile (http://www.plasticgenius.com/2011/08/plexiglass-vs-lexan-matchup.html) My test is that "lexan" can be tortured with vicegrips without breaking

bandsaw might be better because the blade is always going one way but you wouldn't want to scratch up the windshield so cover the saw's table with something..

I have often cut with a hacksaw with blade turned 90 degrees can work well ..if curve is gradual, can do fine......even a hand woodsaw, though clumsy, always cutting straight, progressively "cutting corners off until it's near round-enough for a file... all works better if you have a rounded bit of wood clamped down where you are cutting to stop vibration, if that seems to be happening
 
I've cut two windshields. The one on 1000G Fuller fairing and the one on my Cavalcade. I used a cutoff wheel both times and had great results. yeah it melted the plastic, but that snaps off easily and leaves no damage as the masking tape like Ron suggested protects the surrounding areas. I cut it in two passes. First to establish the cut and the second to cut the rest of the way through. I then block sand the edge with 400 grit on a padded block and then 800 grit to smooth and round the edge. Also, I cut both while they were still mounted on the bike.
120910_0003.jpg~original
130505_0004_zps696f0dc8.jpg~original

151227_0001_zps8awon4ro.jpg~original

160808_0001_zps6cok8yss.jpg~original
 
All done. As I mentioned, I have two identical shields so I disassembled one and placed it over the one I was cutting and used it as a template.

1) Remove from bike
2) Masking tape on shield to be cut
3) Used identical shield as template, dropped it 3.5"
4) Mark with sharpy
5) Masking tape on base of jig saw
6) Cut quickly
7) Smooth cut with orbital sander and 220 grit

Entire process took about 60 minutes. I ran one quick test cut above my desired cut line. The jig saw with a " Plexiglass" blade cut this lexan quickly and without any melting.

Thanks for the help!
 
You must log in or register to reply here.

Similar threads

E
Poor Man's Air Restrictors
Replies
1
Views
90
crazyramen
crazyramen
OldPainless
VM Carb Choke Pickup Tube Replacement
Replies
12
Views
130
chuck hahn
chuck hahn
jharvey
A possibly perforated pretcock
Replies
7
Views
163
rphillips
R
Bobbys 94
78 GS750 engine overhaul on the Cheap!
3 4 5
Replies
81
Views
926
rphillips
R
D
Hi there from Belgium!
Replies
4
Views
84
Suzukian
S
Back
Top