Windshield lowering - How did they do that?

[Mr.Wizard]

When you ride does the top of the windshield cut your eyes? It's perfect height to be right in your line of sight and you need a shield that is an inch or more lower. Problem is you don't want to fork out the cash for a new windshield when yours if perfectly fine. Even then you have a difficult time finding one that is perfect height for you. Well... here's how they do that...

Tools you will need:
Drop Cloth
Painters Tape
Sharpie Marker
Measuring Tape
Poster Board
Razor Knife
Palm Sander or equivalent with #150, 250 and 2000 paper
Dremel Tool with a box of Cut-Off wheels # 409

Time factor: 2 hours

The wife asked me to find a shorter shield as hers cut her eye sight while riding. Problem is it needed to be 1 1/2" shorter and they don't make one that size since it is a Softail. Time to get inventive.

I had her sit on the bike in an upright position. Taking a measuring tape I measured the height from the floor to her eyes. 59". I backed up 15' and using the same 59" for my eye line I could easily see the shield cut her eyes. She made a mark on the windshield with a piece of painters tape, moved it up and down until she was happy with the new height. That was my target cut height.

Once you know how much to cut down the rest is pretty easy. Here are the steps I used.

1. Cover the front of the shield with painters tape. It doesn't have to be pretty. You just want to protect it while you are working.




2. Put your poster board on the chrome stabilizer bar (top of fairing for Touring bikes) and tape it down.




3. Use your Sharpie to make an outline of the top of the shield. You do this while sitting on the bike. This will be your cut pattern.




4. Use a razor knife to cut the pattern while the poster is still on the bike. Wear a pair of gloves in case you slip. Don't worry if you catch the windshield or tape with your razor... that part will be gone soon. Make a smooth cut and stay on your line. A good pattern is key. Use the drawn line as an indicator to stay on track or trim later.




5. Lay the newly cut pattern on a table. Measure from the straight bottom your cut length. If 2" then measure up 2" from the bottom. Use your razor knife and a straight edge to make a good "straight" cut.







6. Tape your pattern to the windshield on the bike. Hold it still and draw your template pattern on the painters tape.



7. Put your drop cloth over the bike handlebars and seat. Ready your Dremel and cut about 1/16" higher than your pattern line. This will give you enough room to smooth out any rough spots you make later. Be patient and make slow but steady moves with the Dremel wheel. You will go though about a dozen cut-off wheels. Wear safety glasses.

Sit on the bike and measure again while looking over the newly cut shield. If it is not low enough repeat steps # 2 through #6. You can reuse the old pattern, just measure again and trim the bottom of the pattern a little more.

8. Once your final cut is made; ready your palm sander with 150 grit sandpaper. Smooth the new cut to the sharpie line as you go. Stop often to feel your progress. Change your sandpaper often to a new sheet.

9. When you are happy with the smoothing and you have matched your drawn pattern you will change to a finer sandpaper to round the edges of the shield cut. I used 250 grit. Don't overdo the rounding. Keep it simple. All you need to do is take the flat edge off the cut and match the factory contour edge.

10. Now take the tape off the shield. Change to a polishing grit sandpaper. I used 2000 Wet N Dry. (use no water) 1000 will do fine if that is all you have. Polish the cut and the rounded edges until glassy smooth.





That's it. Pick up your tools and clean the windshield. You now have a lower height shield that won't cut your line of sight while riding.



-wiz

[icebite1]

Thats about the safest way ive heard of doing it.
Ive done probably a dozen but use a band saw or sabersaw and cut outside the line then use a belt sander down to the line (havent tried a palm sander but will next time) and Wiz's step 9 & 10 to finish

[Mr.Wizard]

When making a custom shield (one with a recurve) shorter...

1. Remove the shield.

2. Tape up the shield with painters tape but do not tape up the bottom where the bolts go.

3. Make a pattern of the bottom of the shield on poster board.

4. Measure your poster board cut height and draw a pattern on the shield/Painters tape.

5. Use the Dremel to follow the pattern.

6. No need to polish as the cut will be hidden when you reinstall the shield.



.

[John Luciano]

That is how I cut mine . That way you keep the factory top edge. Take caution making the holes. Start small.

[saab9k]

When making a custom shield (one with a recurve) shorter...

1. Remove the shield.

2. Tape up the shield with painters tape but do not tape up the bottom where the bolts go.

3. Make a pattern of the bottom of the shield on poster board.

4. Measure your poster board cut height and draw a pattern on the shield/Painters tape.

5. Use the Dremel to follow the pattern.

6. No need to polish as the cut will be hidden when you reinstall the shield.



.

yes that what i will do later.

[joev114]

The "cut from the bottom" method won't work on a newer Harley with a batwing fairing. Look at where the windshield is compressed between the inner and outer fairing on the outer edges. Inside the fairings, the windshield gets wider from that point down. You won't see it unless you take the windshield off (once you do you will know what I'm talking about). It jets out a little bit. I wanted to cut from the bottom but knew that water would get in.

[Mr.Wizard]

The "cut from the bottom" method won't work on a newer Harley with a batwing fairing. Look at where the windshield is compressed between the inner and outer fairing on the outer edges. Inside the fairings, the windshield gets wider from that point down. You won't see it unless you take the windshield off (once you do you will know what I'm talking about). It jets out a little bit. I wanted to cut from the bottom but knew that water would get in.

Hey Joev... I have a 12 TG with a cut from the bottom windshield. The width is about 1/4" short on either side. Doesn't look bad at all.

Guess it depends on how much you want to cut down. I only took an inch off.

[Gorilla]

Hey Joev... I have a 12 TG with a cut from the bottom windshield. The width is about 1/4" short on either side. Doesn't look bad at all.

Guess it depends on how much you want to cut down. I only took an inch off.

Yep I've also done it the way the Wiz says. Works well. Take your time and think about it.