How to Cut Harley Davidson Windshield for a Customized and Professional Finish

Have you ever felt like your Harley Davidson windshield just isn’t the right height for your ride? Maybe it’s too tall, blocking your view, or too short, letting the wind hit you directly in the face. You’re not alone; many riders face this common issue and want to customize their windshields for a better experience.

This article will guide you through the simple steps to cut your Harley Davidson windshield to your desired height. You’ll learn the tools you need and best practices to ensure a clean, professional finish. With the right approach, you can enhance your comfort and style on the road, making every ride more enjoyable.

Key Takeaways

• Customized Height: Determine the ideal windshield height by measuring from the headlight while seated on the motorcycle, often between 12 to 16 inches above for optimal comfort.
• Essential Tools: Gather necessary tools including a measuring tape, permanent marker, utility knife or jigsaw, clamps, safety goggles, sandpaper, and a dust mask for efficient and safe cutting.
• Preparation is Key: Properly prepare the windshield by measuring, marking, and ensuring safety through protective gear and a clutter-free workspace before initiating the cut.
• Cutting Techniques: Use a jigsaw for speed and precision, or alternatives like a circular saw or rotary tool depending on your comfort and available tools. Ensure to cut at a steady pace for best results.
• Finishing Touches: Smooth the edges with sandpaper for a polished finish and clean the windshield using a plastic-safe cleaner and microfiber cloth to maintain clarity and shine.
• Safety First: Always prioritize safety by wearing protective gear and securing the windshield during the cutting process to prevent accidents and injury.

Tools Needed For Cutting

To cut your Harley Davidson windshield effectively, gather the following tools:

• Measuring Tape: Use a measuring tape to determine the desired height for your windshield. Accurate measurements prevent mistakes.
• Marker: A permanent marker helps you mark cutting lines on the windshield clearly. Make sure the lines are visible and straight.
• Utility Knife or Jigsaw: Choose either a utility knife for small adjustments or a jigsaw for larger cuts. Both tools allow for clean edges when cutting.
• Clamps: Use clamps to secure the windshield in place while you cut. This stabilizes the material and ensures a safer cutting process.
• Safety Goggles: Safety goggles protect your eyes from debris during cutting. Always prioritize safety first.
• Sandpaper: Sandpaper smooths the edges after cutting, giving your windshield a polished finish. Opt for fine-grit sandpaper for the best results.
• Dust Mask: A dust mask helps filter out any particles created while cutting. This step keeps you comfortable during the process.

By gathering these tools beforehand, you’ll streamline the cutting process and achieve a professional finish. Make sure to lay out everything in a clean workspace to maintain organization and efficiency.

Preparing The Windshield

Preparing the Harley Davidson windshield correctly sets the stage for a clean cut. This process involves measuring, marking, and taking safety precautions.

Measuring And Marking

Measuring accurately ensures you get the desired height for your windshield. Follow these steps:

1. Determine Ideal Height: Sit on your motorcycle and find the height that feels comfortable. Common preferences range from 12 to 16 inches above the headlight.
2. Use a Measuring Tape: Measure from the center of the headlight up to your preferred height. Take note of this measurement.
3. Mark Clearly: Use a marker to make a clear line where you plan to cut. A straight edge helps achieve a clean, horizontal line.
4. Double-Check Measurements: Before cutting, verify your measurements to avoid mistakes.

Safety Precautions

Safety comes first when you’re cutting the windshield. Implement these precautions:

1. Wear Protective Gear: Safety goggles protect your eyes from debris. A dust mask prevents inhaling plastic particles while cutting.
2. Secure Your Workspace: Ensure your workspace is free from clutter. A clean area minimizes distractions and accidents.
3. Clamp the Windshield: Use clamps to secure the windshield firmly to your work surface. This step prevents movement during the cutting process.
4. Choose the Right Tool: Whether you use a utility knife or jigsaw, ensure it’s sharp and appropriate for the job. A dull blade can lead to slips or jagged cuts.

Following these preparation steps leads to a better cutting experience and a more customized windshield.

Cutting Techniques

Cutting your Harley Davidson windshield requires precision and the right methods. You’ll find two effective techniques below, designed to ensure a clean and professional-looking cut.

Using A Jigsaw

Using a jigsaw for windshield cutting offers speed and accuracy. Start with these steps:

1. Secure the Windshield: Use clamps to secure the windshield to a stable surface. This prevents movement during cutting.
2. Select the Right Blade: Choose a fine-toothed blade specifically designed for plastic or acrylic.
3. Mark the Cut Line: Clearly mark your desired cut line with a marker. Use a straight edge for a precise guide.
4. Cut at a Steady Pace: Turn the jigsaw on and start cutting along the marked line, applying gentle pressure. Let the blade do the work to avoid cracking the material.
5. Smooth the Edges: After cutting, use sandpaper to smooth the edges for a polished finish.

Alternative Cutting Methods

If a jigsaw isn’t available, consider these alternatives:

1. Circular Saw: A circular saw with a fine-toothed blade can work well, but be cautious of overheating. Keep the cutting speed moderate.
2. Rotary Tool: A rotary tool fitted with a cutting wheel provides excellent control for intricate shapes. Move at a slow pace to maintain accuracy.
3. Band Saw: If you have access to a band saw, it’s ideal for cutting thick windshields. Ensure to set it up with a fine blade for best results.
4. Utility Knife: For thin windshields, scoring with a utility knife can suffice. Score along the marked line several times, then snap the excess piece off gently.

Each method requires attention to detail and safety precautions. Always wear protective gear, like gloves and goggles, to safeguard against debris. Choose the method that suits your tools and experience level for a successful outcome.

Finishing Touches

After cutting the Harley Davidson windshield, focus on refining the edges and ensuring the surface is clean. These finishing touches enhance both the appearance and safety of your motorcycle.

Smoothing Edges

Smoothing the edges is essential for a polished look and to prevent injury from sharp edges.

1. Use Sandpaper: Start with medium-grit sandpaper (around 120 grit) to remove jagged edges. Gradually move to finer grits (up to 400 grit) for a smoother finish.
2. Hand or Power Tool: Depending on your comfort level, use either a sanding block for manual smoothing or an electric sander for efficiency.
3. Edge Buffing: Consider using a buffing disc on a rotary tool for professional-quality edges. This step can add shine and remove any small imperfections.
4. Continual Check: Frequently check the smoothness of the edges by running your fingers along them.

Cleaning The Windshield

Cleaning the windshield ensures a clear view and preserves its shine.

1. Choose a Cleaner: Use a plastic-safe cleaner or a mixture of soapy water. Avoid ammonia-based products, as they can damage the windshield.
2. Soft Cloth: Use a microfiber cloth to prevent scratching. Wipe the windshield in a circular motion to lift dirt and grime effectively.
3. Rinse and Dry: Rinse with clean water to remove any soapy residue and then dry with another clean microfiber cloth.
4. Inspect for Scratches: After cleaning, inspect the surface for any scratches or blemishes that may need attention.

These finishing touches not only enhance the look of your Harley Davidson windshield but also contribute to your safety and enjoyment while riding.

Conclusion

Cutting your Harley Davidson windshield can be a rewarding project that enhances your riding experience. With the right tools and techniques you can achieve a customized look that suits your style and improves your comfort on the road.

Don’t forget to take your time during the cutting process and pay attention to those finishing touches. A well-cut windshield not only looks great but also keeps your ride safe and enjoyable.

So grab your tools and get started on transforming your bike into something uniquely yours. Happy riding!

Frequently Asked Questions

Can I customize my Harley Davidson windshield height?

Yes, you can customize the height of your Harley Davidson windshield to fit your preferences. This article provides step-by-step guidance on how to cut and adjust your windshield safely.

What tools do I need to cut my windshield?

You’ll need a jigsaw, a suitable blade, a marker for measuring, safety goggles, and sandpaper for smoothing edges. Ensure you have a sturdy workspace for best results.

What cutting techniques are recommended?

The article suggests using a jigsaw for precision cutting, and also presents alternative methods like circular saws or rotary tools. Always ensure the windshield is secured before cutting.

How do I smooth the edges after cutting?

After cutting, use sandpaper or a power tool to smooth the edges. This step is important to avoid sharp edges that can be dangerous while riding.

How can I clean my windshield after customizing it?

Use a plastic-safe cleaner and a soft cloth to clean your newly cut windshield. This helps maintain its clarity and shine, ensuring a safe riding experience.