How To: Cut Down a Windscreen
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Petty Tyrant
GTS250 GTS300 MP3 500
Joined: 11 Oct 2005
Posts: 29646
Location: Bay Area, California
Tue Jun 03, 2008 6:10 pm quote
Created article How To: Cut Down a Windscreen

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Ossessionato
Midnight Blue MP3 400
Joined: 25 Aug 2007
Posts: 3678
Location: El Pueblo de Nuestra Señora Reina de los Ángeles sobre el Río Porciúncula
Thu Jan 08, 2009 4:17 pm quote
I used these instructions to cut down a tall Fabbri windscreen. Unfortunately, the Fabbri seems to be made of a more brittle material than the OE screen. I could not sustain a cut with my saber saw without the screen cracking and splitting. Having already trashed the screen, I tried different saw blades, all with the same result (including one that said it was for cutting plastic).

What ultimately worked very well was a Dremel tool with a diamond cutoff disk. No vibration, no splitting.
Member
GT200 - Black
Joined: 21 Jun 2008
Posts: 48
Location: Ladysmith, VA
Thu Mar 12, 2009 4:59 am quote
I recently lowered the height of my FACO tall windshield. I took it to a glass shop but they said it was plexiglas and could not guarantee a cut that would not crack the shield.

So, not to be denied, I did the job myself using a Dremel tool with a standard cut-off wheel. It took 2 disks to get the job done, but it worked just fine.
Member
Joined: 11 Aug 2009
Posts: 22
Location: Chicago
Wed Aug 12, 2009 8:32 am quote
does anyone have pictures of what the final product looked like? I am kind of scared of cutting down my windscreen after it cost so much.
Member
GT200 - Black
Joined: 21 Jun 2008
Posts: 48
Location: Ladysmith, VA
Wed Aug 12, 2009 9:27 am quote
I will take a picture tonight when I get home and sent it to you. If you have a cell #, that would be easier.

Ron
Member
Vespa 300 GTS Super
Joined: 18 Jun 2014
Posts: 11
Location: Wilkes Barre, PA
Wed Jun 25, 2014 12:03 pm quote
Dremel Rotary tool instead of a jigsaw?
Does anyone think one of the cutting tools for a Dremel would cut "better" or easier? If so, which tool? (has anyone actually used one for this purpose?)
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 36638
Location: Pleasant Hill, CA
Wed Jun 25, 2014 12:32 pm quote
A dealer I used to use until he got out from under Piaggio always advocated a Dremel - but it used to take his lads ages to cut down a screen, as the Dremel had to be on the lowest speed so as not to melt the plastic, and they had to be very careful not to slip and scratch the screen. I recommend using a jigsaw - less chance of slippage, you just have to make sure the screen is very well supported.
Hooked
2007 GT200, 2008 Yamaha C3
Joined: 27 Jul 2012
Posts: 471
Location: Denver
Sun Mar 20, 2016 3:28 pm quote
I use a 4" angle grinder with a metal blade to cut the bulk of the windshield. I then finish it off with a belt sander and hand sanding working up to 220 grit. Most of these windshields are acrylic. The serrations from even a fine tooth jigsaw are prone to causing cracks. I usually do it with the windshield still on the bike. I cover the scooter with an old bed sheet.
Member
Primavera 50 4TK 4V
Joined: 28 Dec 2015
Posts: 49
Location: Zaanstreek, Netherlands
Wed Apr 27, 2016 10:30 am quote
Thanks for all the info on here! It made me feel confident to cut my own screen down too cos vision in the rain, at night, was next to nothing. Argh!

With my 5'6" I took off 5 inches from the top, using a simple hand fret saw and I think it turned out great.
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 36638
Location: Pleasant Hill, CA
Wed Apr 27, 2016 6:18 pm quote
Excellent result - well done.
Member
2013 Vespa LX 150
Joined: 04 Feb 2017
Posts: 15
Location: UT
Sat Mar 25, 2017 9:12 am quote
I don't like windscreens! But I acknowledge that they keep you warm and help with speed.

After unsuccessfully trying to sell the ridiculously tall screen that came with my LX 150 I decided to cut it down, only because it is wide and covers my hands.

I read the wiki article and followed the tips provided - blue tap to prevent scratching, very fine toothed metal blade instead of plexi blade, don't overheat or will melt and stick back together or get messy, use a cardboard template to draw out the cuts.

I used a small jigsaw and cut off about 12"'. I would have gone shorter but the mounting hardware limited me to that height.

Really emphasize NO plexiglass or plastic blade, this blade is too harsh and only wants to cut straight. The fine metal blade cut so smooth and allowed curving. I also used a water squirt bottle to keep the blade and plastic from overheating.

And then finished off the sharp edges with a palm sander.
Moderaptor
The Hornet (GT200, aka Love Bug) and 'Dimples' - a GTS 300
Joined: 26 Aug 2007
Posts: 36638
Location: Pleasant Hill, CA
Sat Mar 25, 2017 10:14 am quote
Well done.
Hooked
Stella 2005/ Vespa gtv 250
Joined: 14 Sep 2007
Posts: 153

Fri Mar 31, 2017 4:21 pm quote
Kinda low?
Member
2013 Vespa LX 150
Joined: 04 Feb 2017
Posts: 15
Location: UT
Sun Apr 02, 2017 6:18 am quote
That's the point
Hooked
Stella 2005/ Vespa gtv 250
Joined: 14 Sep 2007
Posts: 153

Sun Apr 02, 2017 7:05 am quote
Think I prefer a little higher! Sorry
Hooked
2006 LX150 (carbed) | 2007 GT200
Joined: 29 Jun 2016
Posts: 479
Location: Toronto
Sun Mar 18, 2018 4:53 pm quote
Thanks for the instructions! I successfully removed a few inches from mine today, so now I'm back to an unobstructed view.

It's still a little cold (0C or 32F), which I was worried might make the plastic brittle and more prone to cracking. But it turned out to not be an issue.

I cut the windshield while installed on the bike. Used a reinforced Dremel cutting wheel at about 2/3 of max rpm. Then finished up with some sanding on 150 grit and 220 grit.

Now that I have a windshield, I'm going to get back in the saddle a few weeks earlier than I would have otherwise!
Hooked
Stella 2005/ Vespa gtv 250
Joined: 14 Sep 2007
Posts: 153

Sun Mar 18, 2018 5:21 pm quote
Nice
Hooked
Stella 2005/ Vespa gtv 250
Joined: 14 Sep 2007
Posts: 153

Fri Apr 06, 2018 4:58 pm quote
vespitalabonita wrote:
does anyone have pictures of what the final product looked like? I am kind of scared of cutting down my windscreen after it cost so much.
. I also am interested in cutting mine down. But also worried
Hooked
2007 GT200, 2008 Yamaha C3
Joined: 27 Jul 2012
Posts: 471
Location: Denver
Sat Apr 07, 2018 5:03 am quote
I started out with the biggest windshield you can get. It was on the scooter when I bought it. Kind of made the scooter look like the Popemobile.
Hooked
2013 GTS300ie
Joined: 12 Dec 2017
Posts: 174
Location: Pretoria, South Africa
Sat Jun 30, 2018 6:04 pm quote
I was going to ask why you didn't just buy the OEM mid-sized screen to start with, but then I noticed you said it came with the scoot...?

I do notice it is NOT in the Vespa catalogue, but it is available...

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