Windshield Surgery

Tuesday, Nov 3 2020 [5,723 miles]

I’ve said many times that the stock windshield in the low position was fine. So how come the noise bothered me on a ride, Sunday? Things got better if I hunched down under the windshield or if I stood up. I moved the windshield to the high position. No real change and I don’t like the windshield that high. I won’t be getting a larger windshield. I could try the smaller Adventure R windshield, but thought that might be too low. Instead I decided to cut the stock windshield down. I did this on a GS about a dozen years ago and was mostly happy with the results.

Cut lines

Cut lines

Cut lines
First cut

First cut

First cut

I removed the windshield put some tape on both sides before marking out a cut line that followed the rough contour of the top but about 120 mm lower. When I was happy that the lines were mostly straight and symmetric I put the screen back on the bike. I think that will do.

I used a scroll saw at its lowest speed to cut the plastic. A band saw may have been a better choice but a scroll saw is what I have. The plastic cut well. No melting.

Clean up cut edge

Clean up cut edge

Clean up cut edge

A few more cuts got me closer to my cut line and then I cleaned up the edges using several files. When I finished with the larger files I put the windshield back on the bike and used various needle files for a final finish.

Riders view

Riders view

Riders view
Front view

Front view

Front view

It looks OK. Not sure if I want to radius the top corners. Everything is smooth to the touch. But how does it work?

I took the bike out for a test ride on both back roads and freeway. It is quieter, but I suspect it could be better. The wind is hitting about shoulder height so I am still getting some noise coming up from the bottom of the helmet. Still, an improvement.

I’ll leave things alone for a while and see how I like the ride. I can always make it shorter. Or get the Adventure R windshield.

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