Windshield Chop???

[brightbuell]

I want to chop my shield, just the top couple inches to make it level with the fairing. It will give an illusion of a front drop.

My question is how do you do it so its clean and straight? I have seen several Buells with this Mod. What tools do you use etc? I need the low down!

 

[J_Undisputed]

I'd use masking tape (the good green painters one) to mark the line. Mask it off below the line. Layer the tape on top itself 2 or 3 times over so you have a guide. Then I'd use one of these Plastic/ acrylic knives with light pressure to start drawing across the edge of the tape line. after a several times there will be a slight groove and you can start using more pressure without worry about the knife going astray. Eventually you'll make your way all the way through with a nice clean line. You can use fine file and and plastic polish to soften the edge. That's how i'd do it. There are high speed trim routers, abrasive cutting wheels on grinders and dremels too that will cut acrylic and plastic (which might be how most here would do it). For a one shot deal, there's too much damage i can do with those by accident... so i'd prefer the slow and steady as i dont trust myself.

 

[rrbuell]

I chopped mine earlier this morning actually. Did the prep work last night. I used masking tape from the too of the windscreen down a little past where I was going to cut. The took a ruler and sharpie and measure from the top of the screen down 3 inches. Made a dot and continued to do so until I made it across the whole screen. The connected the dots. Seems pretty remedial but it always gives you the same contour of the upper portion of the screen. Once I have made my line. I used a cutting wheel to score the line I had made. Cut just above the line to give yourself some accidental mishaps you may have. Once I cut all the way through I used a sanding disc to smooth out the edges and for my "ADD" sake I used a light sand paper by hand to fine tune. I like undisputed's idea also. But I used what I had at hand. Turned out awesome.

 

[brightbuell]

Did you do it on or off the bike? I have mine off already just curious and can you guys post pics please!!

 

[rrbuell]

Did mine off. I'll post a pic when I get to the house

 

[brightbuell]

I'm going use blue painters tape several layers to make my line, I will also use a ruler and try the plastic cutting hand tool and follow up with a super fine plastic friendly sand paper and use a small block of wood inside to keep a nice flat edge and lightly even out and round the edges then go to a polish. I have never done this before so thank you both for all your info.

I will let you all know how it went. I wont start until i see your pics.

 

[rrbuell]

It won't let me upl

 

[rrbuell]

Oad pics but the way you are going is a combo of the two methods. It will turn out awesome. I will post pics when allows. Happy modding

 

[heagachongoose]

I did mine with a table saw and a barrell sander. First take it off the bike (believe me it makes it 100000000990 times easier to control what you are doing). Mark your center point at the lowest point of your chop. Make a rough sketch going from the low center point to the high left/right corners. Do a rough cut with the saw making sure not to cut too much or get too close to your curve. Then bring it to the barrel sander and even out your curve and make it look pretty. Piece of cake.

 

[rrbuell]

^[up]

 

[brightbuell]

Google search is so much better then the search engine on this forum.

OK, I ended up using my dremel and it was way faster, i had cut about 8 vertical lines down to the scratch i started with the plastic knife using my larger hand held grinder with a cutting wheel. Then used the dremel to cut the scratch i started while removing one piece at a time. I did the vertical lines because when you cut it melts and then rehardens so i found it to work great by removing each piece separately because it would still be melted and peal right off, if i had cut all the way it would re harden before i got half way through. Once i had the top removed i used my dremel with a sanding bit to remove all the jagged crap. Then i went to a fine sand paper and it's now 98% done i'm just waiting for the plastic polish i ordered to polish the whole shield to make it look new again.



Once i started using power tools it only took about 15min. Put it this way i am blown away with how good it turned out. I really did not needs the plastic cutting knife, that added an hour and i only got half way through with it. I was making more mistakes with the plastic knife that any of the power tools. I made no mistakes with the power tools..

So my advice if you don't have a barrel sander and a table saw, is to use good bits with a dremel like tool and you will do just fine. You will need a cutting bit, a sanding bit and a polishing bit then some real fine sand paper, last plastic polish. You are good to go.

 

[rrbuell]

Awesome buddy. It looks great. Glad you figured it out

 

[STL XB12Ss]

Looks good. [up] What kind of plastic polish did you buy? I was thinking of running some 3000 grit over my plastics, but I am hesitant because I want to make sure it polishes out slick.

 

[brightbuell]

This is what i ordered., i hope its the right thing. It says it will polish plastics and soft metal.


http://www.homedepot.com/p/Ryobi-4-oz-Plastic-Rouge-Buffing-Compound-A01AG162/100520871#.UiZ6Uja1Gk0

 

[EricS]

3000 will probably look scratched up. Was polishing my airbox and 2500 looked awful, used Novus polish on it and looks better than before.

 

[STL XB12Ss]

Yes, it would definitely be hazy and scratched up. I don't plan on leaving it unbuffed in 3000. We have good compound at work for buffing fresh paint after nibbing but I'm not using it on my plastics. I have heard good things about Novus, but haven't seen it in action yet. Keep us posted on how it turns out. [up]

 

[brightbuell]

OK, i just found that i already had another plastic polish called ( Professional Super Premium Polish Paste ) any way i used it with out a power tool and it is 75% better then it was in my last pic. I have another finishing plastic polish too in my shop but i don't have an adapter tool to get my 5/8" grinder to become a polisher tool. I can not find a polishing ball of any kind that will fit on my 5/8" / 16mm grinder?? WTF!! At this point it is almost done but i really need to buff it to get the light swirl marks out. Any know of a 5/8" tool like that. i Googled everything and Ebey etc.

 

[Sirius815]

Elbow grease! [up]

 

[brightbuell]

Another hour later about two polish sessions. Im only using my hands, a cloth and some polish. Still needs to be buffed but i can put it on like this until i find a polishing ball cheap for my grinder. 99% done

 

[Sirius815]

Can't wait to see it on.