Cutting and fitting a new windshield to a GK

[Eli69]

here's how i cut the windshield on my windjammer. i used a spiral saw and it went very easily. i took my pictures after the fact so here's what it looked like before:



i needed something round to trace out a curve. this frisbee looked about right:



i cut my line free hand with the spiral saw which had a special plastic cutting blade. i put my finger between the saw and the windshield to keep it from scratching.



i ran the belt sander across the top a few times to even everything out. then at a slight angle to take off any sharp edge. here's the finished product.




i think i slipped a little with the belt sander, you can see a little scratchiness near the top. it's good enough for the bike i call "the ugly". so all done now, time to throw the frisbee for the doggy.

 

[Guest]

Hey Eli69.

Congrat.

How do those vents work for you?

 

[60ratrod]

An excellent example of the motto I live by in the garage:

If you need it and don't have it or can't get it, make it or modify it.

And to protect something from being scratched, all you have to do is apply some tape. Professional autobody techs will tape a painted hood or panel if they have to cut into it, for say like a hood scoop, to keep the paint from being boogered up. Some very fine sand paper will take those scratches out. But you have to use like 5000 grit to do it

 

[Eli69]

Hey Eli69.

Congrat.

How do those vents work for you?

the windshield was old and scratchy. i couldn't see through it well at night. that's the main reason i cut it down. it was also too hot for me behind that big window. i really can't tell if the vents do anything but they can't hurt. when it gets cold in the fall i'll see if i'm any warmer with them closed. at that time i'll probably miss that big windshield but i'm sure i'll just deal with it.

 

[Steve]

i really can't tell if the vents do anything but they can't hurt.

The vents in a Windjammer windshield really don't do much for ventilation. Their main purpose is to relieve some of the vacuum behind the windshield to keep the "bubble" of still air from collapsing.

With the cut-down shield, there would not be as much vacuum, and the vents are even more worthless, but the only way to remove them is to buy a new shield.

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