Glass or plastic?

 

Plastic.

 

5" makita grinder with a zip disk and proper backing plate with guard. Then sand the edge afterwards with a sponge sander.

 

I just did this last week. I used a dremel tool with a round high speed steel bit. Worked great!


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What windshield and light bar did you use? I'm thinking of using utv giants 30 in cree with mounts that fit in the bends of roll cage but not sure if they will clear the roof. Can't believe no one has come out with a combo that fits windshield,roof, lightbar.

 

The polaris full shield and the bar and light came off E bay as a combo. And it clears the roof fine. I think it turned out great.

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tape and jigsaw works great

 

I use a jig saw with a fine tooth blade, and it works really well.

 

I use an air saw with a fine blade to cut to size and trim out any wavies with a 2" disc on an angled die grinder and finish out with 400 wet/dry paper. I trim 30-40 bike windscreens a season and usually have them done in twenty minutes. MAsk it with blue tape mark with Sharpie and go for. I the rider isn't sure how much he wants off I'll trim it and sent him out for a ride to see how he likes the height and finish it later. Jes like chopping a top on a car, mark it off and go for it!

 

I have used a skill saw with a plywood blade. Set the guide shallow if you do this

 

This bit in a Drimmel works great ..

Duane

 

One item I failed to mention is a single cut mill file that I only use for plastic before starting the sanding, and when sanding use a block. It helps keep from getting any low spots.

 

The simplest to cut lexan/polycarbonate/plexiglass is with a tin snips. It takes some hand muscles, but no sanding, no polishing. Just cut and done. If you can use a tin snips halfway decent, it looks like a factory edge. Been doing this for years with polycarbonate race car windshields. Buy a decent brand snips, like Wiss or similar. About $10-$15.

Btw, you can bend poly/lexan with a metal brake.

 

Also a good tip, tape the Area and draw your line over the tape and just cut thru ot