how to cut a motorcycle windshield


Cutting a motorcycle windshield is a task that requires careful planning and the right tools. Whether you’re trimming an existing windshield to a specific size or customizing it to your preferences, here’s a step-by-step guide on how to cut a motorcycle windshield:

Materials and Tools You’ll Need:

  • Motorcycle windshield
  • Measuring tape or ruler
  • Masking tape
  • Pencil or marker
  • Safety goggles
  • Dremel rotary tool or a jigsaw with a fine-toothed blade
  • Clamps or a vise
  • Sandpaper (various grits)
  • Polishing compound (optional)
  • Microfiber cloth


  1. Prepare Your Work Area:
    • Choose a well-ventilated workspace with sufficient lighting and a clean, flat surface to work on.
  2. Measure and Mark:
    • Determine the desired height and shape for your motorcycle windshield. Use a measuring tape or ruler to mark the measurements on the windshield, making sure they are straight and even.
  3. Apply Masking Tape:
    • To create a guideline for cutting and prevent the windshield from splintering, apply a strip of masking tape along the marked cutting line.
  4. Secure the Windshield:
    • Place the windshield in a clamp or vise to hold it securely during cutting. Make sure it’s stable and won’t move while you work.
  5. Put on Safety Gear:
    • Wear safety goggles to protect your eyes from debris and wear appropriate clothing to shield yourself from flying particles.
  6. Cut the Windshield:
    • If using a Dremel rotary tool:
      • Attach a fine-toothed cutting wheel or a fiberglass-reinforced cutoff wheel to the Dremel.
      • Start cutting along the marked line, following the masking tape as your guide.
      • Keep a steady hand, and move the Dremel smoothly along the line. Avoid applying excessive pressure, as it can cause the plastic to melt or crack.
      • Take your time, and make precise cuts until you’ve completely severed the excess portion.
    • If using a jigsaw:
      • Use a fine-toothed blade suitable for cutting plastic.
      • Start cutting along the marked line, ensuring that the windshield is secured in place.
      • Maintain a steady hand and a slow, controlled cutting speed to prevent chipping or cracking.
      • Use a light touch and let the jigsaw blade do the work.
  7. Remove Rough Edges:
    • After cutting, you may notice rough or jagged edges along the cut line. Use sandpaper of varying grits (starting with a coarse grit and progressing to finer grits) to smooth and shape the edges. This will give your windshield a finished look.
  8. Polish (Optional):
    • If desired, you can apply a plastic or acrylic polishing compound to the newly cut edges to enhance clarity and remove fine scratches.
  9. Clean and Install:
    • Thoroughly clean the windshield to remove any dust or debris. Use a microfiber cloth and a plastic-safe cleaner.
    • Install the windshield on your motorcycle according to the manufacturer’s instructions.
  10. Test Ride:
    • Take a test ride to ensure the newly cut windshield meets your visibility and wind protection needs. Make any adjustments if necessary.

Always exercise caution and prioritize safety when cutting a motorcycle windshield. If you’re uncertain about the process, consider seeking assistance from a professional who specializes in motorcycle accessories or windshields.

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