Making The Perfect Windshield For Your Motorcycle
If your motorcycle's windshield is annoying you in any way
, it is time for you to make the change. You can alter your shield to be exactly how you want it to be with these simple steps.
There are generally two schools of thought on what constitutes "the right height." You are either a rider who wants to be comfortably ensconced behind a large enveloping view port, or one who appreciates the protection of a windshield but feels most comfortable being able to see over it.
There is no need to remove too much material on the first cut. It's easier to try a smaller amount and test it out.
Then, if needed, cut some more. Generally, you should be able to see over the upper edge of the shield when seated comfortably.
Sit on the motorcycle in as comfortable a position as possible and carefully mark the new upper edge with something nonpermanent such as a crayon, grease pencil or a piece of masking tape. You're now almost ready for surgery, but we still have to figure out the right shape.
Unless you have something extraordinary in mind, copying the original shape or curvature of the existing windshield is probably the best way to go. You can do this by making a pattern.
To copy the existing shape, place the card stock or art board behind the windshield and carefully trace the upper edge. Cut the card along the line you have traced, and you've got your pattern.
You could just mark the plastic to make your cut, but you'll need to protect it from the inevitable scratches the tools will make. Masking the area that will be cut provides the protection you'll need and an ideal surface to mark the cut line.
Mask a large enough area to cover where the new cut will be plus a little beyond, this will keep the jigsaw base from scratching the plastic. Avoid using something like duct tape because some tapes use solvent-based glues that could damage the surface of the plastic.
Mask both the front and the back of the shield. You have reached the point of no return -- it's time to make the cut.
Now's the time to drape the sheet over your motorcycle; it will make clean-up a breeze. Begin making your cut at one edge.
Right-handed people will find it easier to cut from right to left. Make a smooth cut by applying steady pressure but don't try to go too fast.
You're trying to cut the plastic, not burn through it. Care at this stage will reduce the amount of work necessary to finish the edge later.
Keep the saw base flat against the taped surface and hold the plastic with your free hand to minimize vibration. When your cut is complete, it's time to finish the edge.
Resist the urge to remove the tape at this stage because it will continue to help prevent scratches from misplaced filing and sanding. The first stage of finishing the shield's new top edge is to remove any saw marks and smooth out undulations in the cut.
You can do this using the flat file and making long strokes along the edge. When you are satisfied that your newly cut edge is smooth, round it slightly.
Use the existing edge from the section that you've cut from the windshield as a guide for the shape. After the filing is complete it's time for sanding and polishing.
A block sander is ideal for this next step because it's easy to handle and change sanding papers. Begin with a coarse or medium paper.
A general-purpose or wood sanding paper is all you'll need. As the edge gets smoother, switch to finer grades of paper until you've polished the edge to a finish that is similar in smoothness to the original.
You should be able to reach this level of smoothness with extra-fine grade or 220-grit paper. Again, use the original part as a guide for shape and final finish.
Wipe the edge clean and use a plastic cleaner/polish to complete the job. Sure, you can use power sanders for finishing the edge.
But remember, these tools were made to remove materials easier and faster. They can help you make mistakes more quickly too!
Remove the sheet and dust from the motorcycle, and you're ready for a post-operative test ride. Cutting a windshield is a relatively easy modification that can help you see properly in all conditions.
In the end, you will have the satisfaction of customizing a bike to your personal specifications while making it safer, too. Get out there and try!
by: Jack Landry
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