How to Cut Down a Motorcycle Windshield

You'd love to get the motorcycle out of the garage and onto the road on a nice day, but that windshield you have seems to be a bit too high. Ideally, it should be at approximately nose level. Save money from buying a new one, and cut down your motorcycle windshield. In the long run, you can see more clearly when you ride.

Things You'll Need

• Blue masking tape
• Jigsaw with wood blade
• Cardboard
• Sandpaper, 80- and 220-grit
• Palm sander or wood block
• Methyl ethyl keytone (solvent)
• Rags
• Old sheet

Instructions

1. Determine the height you need the windshield to be. Sit on the motorcycle, and mark the windshield with masking tape. An ideal level is just below your eye level, about even with your nose.

2. Take the motorcycle for a ride to ensure that the level you have marked is where you want the cut. Leave the tape on for a few days, if necessary. Get comfortable with where you have placed the tape. Once you are sure, you're ready to make the cut.

3. Remove the windshield from the motorcycle. Make sure the tape is at least 4 inches high, on both sides of the windshield so to protect the windshield from scratches when you cut.

4. Use a jigsaw with a wood blade to cut along the top of the tape. Go slowly and evenly. Place a thin piece of cardboard over the outer, curved edge of the windshield when you cut. Remove the tape.

5. Stand the windshield upright, wrap an old sheet around it and sand the cut edge. Start with 80-grit sandpaper in a palm sander or wrapped around a wood block, then repeat with 220-grit for a smooth finish.

6. Apply a very thin film of a universal solvent, methyl ethyl keytone, which "melts" plastic, by placing a small amount on a rag. This gives the windshield a very smooth, clean edge. Re-attach the windshield to your motorcycle.

Tips & Warnings

• Start by cutting off a small part of the windshield and see if it's enough. You can always cut more off later, but you can't put it back on once you've made the cut.

• Test the methyl ethyl keytone on the piece of the windshield you cut off before applying it to the windshield itself. Get an idea of how much to use and how to apply it.

• You can also mark the windshield where you want to make the cut with a crayon or grease pencil too.

• Don't go too fast with the jigsaw. The blade can heat up and melt the windshield's plastic.

• Don't lay the windshield down after cutting and sanding without covering it. Dust and particles can scratch the windshield's surface.