Cut my windscreen down

Vatu · May 8, 2021

My old windscreen was crazed so I bought a new one on Ebay (only around $60.) However, it was taller than I expected so, after some soul-searching, I decided to cut it down. I did it in two 1.5" increments (first time wasn't enough, so I did it again.) Process: 1) Mark screen with marker. I used tape to provide an edge for market to ride on), 2) I used a Dremel tool with a metal cutting brade and mostly just burned thrhough the plastic, 3) Use an air-operated die grinder with a flat wheel and #60 grit paper to remove the melted plastic and smooth the edges, then a finer grit paper (around 200) to smooth it a little more. Bottomline, it was easy to do if you have decent tools. Pleased with the results. I posted this in case anyone else's windscreen is too tall.

Photo 1: Marking the screen with tape for a guide

Photo 2 (below) Going after it with the Dremel. Mostly melts the plastic, rather than cuts.

Photo 3 (below): Looks really ugly until sanded off.

Photo 4 (below): Shows removed strip

Photo 5 (below): Shows finished screen

Krons · May 8, 2021

Nice! I've been been meaning to try this, haven't gotten the guts to do it yet. I've been wanting a short "summer" screen and will give it a go.

Already have a replacement for my current one that'll be my tall screen.

GrayBeard · May 8, 2021

I have a shorty windscreen that barely covers the instruments that I like to have on the bike if I'm going to be off in the woods.

Normally I have the tall Puig screen on it for road trips.

VTBMWGS · May 9, 2021

GrayBeard said:
I have a shorty windscreen that barely covers the instruments that I like to have on the bike if I'm going to be off in the woods.

Normally I have the tall Puig screen on it for road trips.

Very nice. The shorty is my next purchase. I have the Puig touring along with the stock screen which is nice, but for the hot months of forest roads it would be nice to have the wind hit the vents on my helmet.

JoeFishNC · May 8, 2021

if you have a torch, small one, you can quickly do the edges and it will roll them and smooth them out. I cut the windscreen of my previous bike. BTW they make a Plastic cutting blade for a jig saw that works very well.

Krons · Jun 3, 2021

@JoeFishNC tried the torch method and got some distortion and fine cracks...too much heat? This was on a stock GSA screen.

Maybe I should have stuck with sanding...may plastidip the screen black anyway.

Vatu · May 9, 2021

Thanks. I'll try the torch on the section that I cut off. (However, the sanded sections look great, without the torch treatment.)

molly · May 9, 2021

I mentioned this method in another recent post. I have adopted the same approach on a number of different bikes over the years and invariably it has been successful.

bosnjo · May 9, 2021

I still didn't give up the idea of fabricating Givi Airflow out of Givi parts. I have Givi Touring screen, that should be cut down to almost half, I have clamps for Givi Airflow and just need to purchase top portion screen that is universal across all Givi Airflow sreens and is sold separately.

Cut my windscreen down

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