How to Trim a Harley Windshield
If the windshield on your Harley Davidson is too high or you don't think the style goes with the look of your chopper, you can trim it down or into another shape without compromising the finish. You can have this done professionally or you can try to do it yourself.
- Masking tape
- Sabre saw or bandsaw
- 80 grit sandpaper
- 220 grit sandpaper
- Methyl ethyl ketone (M.E.K.)
Determine how much you need to cut off by masking part of the windshield and seeing how you can live with it. At first you may be conservative with your masking, but you can lower the masking until you find a height you can comfortably see over when settled in the seat.
Remove the windshield from your Harley.
Trace the final outline of your masking tape onto cardboard and cut it out.
Place masking tape on the outside of the windshield around where you will cut. About 2 inches on either side will suffice.
Trace a cut line on the masking tape using the cardboard cutout as a template.
Cover the front of the windshield with cardboard or plastic to protect it from scratching.
Use a sabre saw to trim along the cut line on the windshield. You should cut from the front with the outside of the windshield up.
Stand the shield upright and sand the rough edge with 80 grit sandpaper.
Go over the sanded edge with a 220 grit sandpaper for a smoother finish.
Wrap a cotton rag around you finger and dip it in methyl ethyl ketone (M.E.K.) a universal solvent available at home improvement stores. You want the cotton to be moist but not dripping.
Wipe the edge in one motion with your moistened finger. This melts the plastic windshield edge and creates a smooth factory finish.
Replace the freshly trimmed windshield on your Harley.