Anyone cut a screen successfully?

[Dooly]

I'm looking to cut a few inches off the top of the screen.
Anyone done it, and what did they do it with?
I don't want to risk wrecking the screen as the odds of me getting another are low.

[crazefox]

yip a cut of wheel works

[piston broke]

i use a router to cut 3mm acrylic.
a screen should be alright.
use a 5mm diameter or less bit,and use a guide so yo don't run off track.
p.s do a trial on a broken one first so you are confident.

[Bonez]

As well as the suggestions above a band saw with a fine toothed blade should be ok too. I've used a jigsaw once too. Make sure you mask out the screen to prevent further scratching.

[hayd3n]

same as above fine bandsasw or fine jigsaw with masking tape to stop it marking screen u can use methsto clean screen and wont mark damage plastic(DONT USE THINNERS!!!!!!!!!!!!!!!!!!!)

[imdying]

Cut off wheel on a dremel, then a 10mm diameter sanding drum to clean it up, then sandpaper to finish.

[CookMySock]

Use the router or the dremel. Cut off wheel in a grinder will chatter and grab and probably smash it unless you insert only the very edge of the wheel or you can hold the job down securely (leave it on the bike?) Ditto for the jigsaw.

You could put the part you want to cut off in the vice and cut with the hacksaw but I think you will crack it unless you are exceedingly careful, and even then, I think you will still crack it.

Finish shaping with a woodblock and 200 grit, or very very carefully with the belt sander(!) and then progressively right up to 2000grit followed by polishing compound and a buffing wheel.

I did a bit of the clear perspex / polished aluminium / LEDs thing with really cool results, but yeah it splits so damn easy.

Steve

[Dooly]

Sounds good, cheers guys.

[robinm]

another tip is to warm the screen up,just the area you wish to cut, with a hot air gun, not too hot, just warm. Then you can actually cut it with a decent heavy pair of scissors. Also if it is an old screen then unless you warm it up then no matter what you cut it with it will proberly crack.
Go to a wrecker and pick up some broken ones and have a play before you attack your one.

[JimO]

skillsaw with the blade in backwards would do it

[hayd3n]

skillsaw with the blade in backwards would do it

huh???????????????????

[JimO]

huh???????????????????

well it would cut it no worries, wouldnt be pretty though

[imdying]

If it grabbed it would shatter it. A jigsaw is actually pretty good at cutting perspex, but I would only recommend it on flat sheets that you can clamp down.

[Dooly]

Have'nt tried it yet.
Its sitting on the table inside ready to go.
May try tonight.

[vifferman]

Dooly, there are a few people on the VFR forum who have cut down their windscreens - usually the ones who own the 2002-2008 models which have a higher screen than the earlier models. I tried to find the best post/thread about this that showed what they did and how they did it, and this one was the best I could find.
Basically, it seems that the first trick is first to tape off the screen so the area you're cutting and the area next to it are covered up, to stop scratches and help stop it cracking.
The next most important bit is that whatever you use to cut it has small teeth on the blade, so it doesn't snag and grab the material. It seems various people have used either air-powered cut-off tools, or jigsaws. I've trimmed a seat cowl successfully with a laminate trimmer; it's ABS, not polycarbonate like most windscreens, but the principle is the same. A high-speed tool is good, as it doesn't snag as much or stress the plastic as much as something moving slowly.
Take your time.
Use some fluids (but not beer - save that for rewarding yourself for a job well done!) to help with cutting and flushing away polycarbonate from the teeth of the blade.
Finish up by sanding or filing the cut edge smooth, including carefully rounding the edges slightly, then use some plastic polish or similar for a really smooth edge.
Good luck!