How to Cut Down a Harley Windshield

For safer riding, you need the windshield at the right height.

If you enjoy riding your Harley just down the road or to the annual rally in Sturgis, South Dakota, you need a windshield cut to the proper height for safer riding. A windshield too high can collect dust, dirt or raindrops that obscure your vision making it dangerous to ride. You can cut the windshield down to proper size with just a few materials.

Difficulty:

Moderately Easy

Instructions

Things You'll Need

• Blue masking tape
• Thin cardboard
• Old sheet
• Marking pen
• Protective eye gear
• Jigsaw with a fine-toothed blade
• Sandpaper, 80 and 220 grit
• Block of wood
• MEK (Butanone)

1. • 1

     Test-drive to determine the proper height for your windshield. Remember the point on your windshield that you look through. You will cut the windshield down just below that point.

   • 2

     Cut off a long piece of blue masking tape. Stick the tape in the area just below where your line of vision was when riding. Before you do anything more to the windshield, take another text ride. This will confirm whether you have the masking tape in the right location. Adjust the masking tape higher or lower if needed.

   • 3

     Make a pattern of your windshield's curvature. Place a thin piece of cardboard over the windshield, and trace along the windshield's outside edge with a pencil or marker.

   • 4

     Cut out the cardboard pattern.

   • 5

     Cover your worktable with an old sheet. This will keep your windshield from becoming scratched.

   • 6

     Remove the windshield from your Harley--do this very carefully so you don't scratch the windshield or your Harley. Lay the windshield on your worktable.

   • 7

     Cover the windshield on both sides with blue masking tape. This will give it extra protection from getting scratched.

   • 8

     Place the template pattern on the windshield. Trace around it on the blue masking tape with a pencil or marker.

   • 9

     Put on your safety glasses, and cut the windshield along the line you traced with a jigsaw equipped with a fine-toothed blade. Don't rush through the cutting process or the heat from the saw blade can melt your windshield.

   • 10

     Pull off some of the masking tape along the outside edge of the windshield. You need enough of the windshield exposed so you can sand the edge of the windshield.

   • 11

     Stand the windshield in an upright position. Someone should hold the windshield for you so it doesn't fall over when you begin sanding.

   • 12

     Sand the edge of your windshield with 80-grit sandpaper attached to a small block of wood. Sand the edge again using 220-grit sandpaper.

   • 13

     Wrap your finger in a cotton cloth and dip it into some methyl ethyl ketone, also known as MEK.

   • 14

     Run your wrapped finger along the edge of your windshield. This will give you a smooth finish.

   • 15

     Remove all the masking tape from the windshield. Reinstall the windshield on your Harley.

Tips & Warnings

• To help keep your windshield from getting scratched when you are not riding your Harley, slip an old T-shirt over it.

• Do not drip MEK anywhere on the windshield, because it will mar your windshield.