How To Cut Plexiglass
HOW TO CUT PLEXIGLASS
IT'S EASY TO MAKE THAT WINDSHIELD FIT YOU.
Windshields are wonderful things to keep wind and rain and bugs off the front of motorcyclists. Ducking behind a windshield is fine when the weather is nasty, and it’s not a problem when the weather is fine, but it can be nice to see over a windshield, too. And that’s not possible with all windshields.
One-size-fits-all windshields and fairings are particularly afflicted with oversized windscreens. They are made to fit motorcycles with steering heads of differing heights. When the headlight is high, the fairing or windshield is high. And then the rider may not be able to look over the windshield.
There is a solution for the too-tall
windshield. It’s the saw. Plexiglass turns out to be an easily cut material, and it’s not difficult to trim windshields.
The tools you’ll need are a sabre saw with fine-tooth blade, masking tape and sandpaper or a file.
The masking tape goes over the front side of the windshield near the top, and it extends down a couple of inches lower than where the cut will be made. This protects the windshield from scratches and gives you an easy surface to mark the cut. With the tape applied, use a crayon or pen to mark where the top of the windshield will be cut. Usually it’s best to follow the shape used with the stock windshield height, though it's just as easy to square off the top or make it more rounded. With the line drawn, the
sabre saw is used to cut through the plastic. A hacksaw blade in the saw works best, and if you use a variable-speed sabre saw, try limiting speed to about twothirds. Make sure you hold the saw firmly on the plexiglass surface, but don’t bend the shield or put so much pressure on that you break the windshield. After the saw cut you can even up the top edge with sandpaper or a file, though a power sander, either rotary or belt, can do a better job of smoothing and evening the top edge.
All that’s left is to take off the tape and make sure the cut is in the right place. If you’re not sure how much to take off, make a shallow cut and ride the bike for a week to see if you need more off. It’s a lot harder to add material. 0
