How to cut down a windshield

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CelticCross
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How to cut down a windshield

Post by CelticCross »

Throwing this out there in case it is of benefit to the forum.

1. Mask off the area on the windshield where you will cut. Use painters or similar tape and extend the area large enough to help prevent the foot of the jigsaw from marring the face of the windshield. The tape will also help chipping the windshield while cutting.
2. Mark your cut line. Caution: if in doubt, it is best to err on the side of caution as you can make a second cut if your windshield is too long after the first cut. If you cut too low, you are stuck with your results or need to buy a new windshield which would be an expensive proposition.
3. Place the windshield on a flat surface for cutting. Placing a towel over a foam pad will help cushion the windshield and help prevent scratches while cutting.
4. Carefully cut the windshield using a fine tooth blade on your jigsaw. Don’t hurry – let the blade do the work. At the same time, don’t go so slowly that the blade heats up and starts melting the windshield. If you want to test your cutting style, choose a location an inch or more above your desired cut line. Once satisfied with your results, start your real cut.
5. Mount the newly shortened windshield on your scooter and check to see if the windshield is at the desired height. If not, remove it and repeat steps 2-4.
6. Using a sanding block and medium and fine sandpaper, or a fine metal file followed by fine sandpaper, smooth the freshly-cut surface and edges. Make minor adjustments to the contour if needed. Remove the tape and clean the windshield.
7. Ride and enjoy.