Modern Vespa

I have been riding with the large Vespa windscreen for two weeks. I knew it was too tall but thought I'd try it and see how I liked it. Its awful!! I don't like looking thru it - seems to blur the world; nearly impossible to see thru when the morning mist settles on it (virtually every morning here in Santa Cruz); and when its hot I got virtually no breeze.

I'd built custom windscreens for my last two scooters (Metro and Vino) so I knew I could cut it down . It took about two hours. I took pics of the procedure, wrote it up, and was going to put it in the Wiki but saw that Delaware Don and London Charles had already documented virtually the same procedure that I used so I refrained from adding my version.

https://modernvespa.com/forum/wiki-cut-down-windscreen

My procedure differed a little tho. I cut the winscreen square first and then used the cut off as a french square for the final shape (see pics below). I used a drill with a sander attached to clean the shape up (see pics below). Even though I'm pretty good with cutting a line with a jig saw, the cut line was not perfect. The sander with 80 grit made short work of the edges. Work slowly and don't keep the sander in one spot. Also, I handsanded from 80 grit to 400 grit (I'm a furniture maker and had the paper) being VERY careful not to scratch the inner and outer surface. You can't feel any difference between my edge and the factory edge.

Here's the final result. The absolute best height for the windscreen is just below you eyes so that you can see over it in all conditions while getting the best wind protection. The windscreen I built for my Vino was about 1" too short and it blew into my helmet on cold winter mornings, I'd scrunch up just a bit to avoid the wind. This windscreen height is almost perfect for me.
Miguel

PS - Sorry about the order of the photos, I couldn't figure out how to edit the order without reloading and annotating them again.

Hi Miguel,
Do you make furniture for a living? I'm a furniture designer/maker as well. I currently teach art and have taught woodshop as well. Do you have a website? You can check out some of my work here:

[url]www.changerang.com[/url]

Let me know what you think!
Aaron

Nice job, Miguel. I cut mine down this spring, too, and think I took a little more off than I should have. I still think I like it better than full height, though. At least if yours is a little too tall you can still trim it some more.

I'm a serious amatuer. I went to furniture making school in Boston instead of highschool (pretty common there) and have been making furniture most of my life. I don't have a website per se but some of my work is on my wife's art site: [url]www. teresamallen.com[/url]. Click on architectural details (shows our house). We design and build everything.
Miguel

A lesson learned many times over in furniture making. Woodworking is all about removing wood and fitting peices together. Once you remove wood, you can't put it back.
Miguel

Like the solar lamp and cloud bench - very uniqe I really like the asymmetry of the back. My work is more in the arts-and-craft and Japanese style but with twists.
Miguel

Beautiful job! I'm such a spastic when it comes to tools. I just bought mine already cut down.

nice work! i've cut down two tall screens now and have been really happy with the results both times. if i ever do another one i think i'll probably use a dremel - i've been using a jigsaw and finishing with a hand file then sandpaper - the result is fine, but the windscreen does tend to dance about under the jigsaw blade and i've yet to find a really good way to clamp it.

Good article, Miguel. This was a topic on the forum about a week ago or so on the tall windshields (of which I have on my '08 GTS also) and I will eventually build up the courage to take a sabre saw to mine too, as it is so tall. When I do, I hope mine turns out to be as good a job as yours looks.

Genie, The key I think is using a fine tooth blade and making sure that the jigsaw is not in orbital mode. Most jig saws today have a setting that allows you to put it in aggressive mode where it pushes the bottom of the blade out at the bottom of the stroke. It makes for a very aggressive cut but does increase the need for clamping. Make sure the orbitting feature is turned off. The picture below shows the orbital mode setting turned off on my Bosch jigsaw and, for reference, the blade that I used. I didn't find the need for clamping and was able to hold it down easily by hand - no need to clamp it. BTW, I cut from the front side of the glass.

A Dremel tool would worry me. One small slip of the tool and it could run across the glass ruining the windsceen.

Migue

Go buy some 1/8" plastic from Tap Plastics or someplace like that and practice a bit. Is pretty easy as the plastic cuts like butter.
Miguel

Miguel, your windshield turned out well.

I used a Dremel tool with the long extension accessory to cut down two shields on Vespa's: No problems. I just ordered the tall Vespa shield for my GTV and I will use it again. I did a small, test cut on the first shield that I cut, using my jigsaw and didn't feel comfortable with it............... so I switched to the Dremel with a diamond cutting wheel and it worked like a charm. Different strokes for different folks.

I would never have thought of using a dremel tool but there's many ways to accomplish the same task. Did you use it like a router or freehand like a pencil(which is what I was thinking of when I replied to Genie). Thx. Miguel

I taped it off (like you did) and followed the line, freehand......very slowly. The long, accessory extension and the fact that I have a cordless Dremel tool is probably why it worked so easily for me. I think it wouldn't have worked so well with a plain Dremel tool. The extension tool is very light and allows you to maneuver the tool easily.

What's the name of the sanding attachment you used on your drill to smooth off the edges?
I cut my WS down also, right on the GT200, using a Dremel with a cutting wheel.
It's a good height now, but the edges came out rough and jagged and the more I tried to smooth it out the worst it got.
So I put black door edge moulding around the edges...

The WS looks fine now, but the upper black moulding just below [and sometimes in] my line of sight is annoying...
I'd like to remove it and so would greatly appreciate some tips on how to get the windshield's rough upper edge
sanded down to a smooth round surface??

Much thanks,

About a month ago, I cut down my tall Vespa windscreen on the GTV. I also cut it down a bit too much.

SO, better to cut it tall and possibly having to recut, than to cut it short and living with the results.

I can't complain though cause it still is fantastic. Thanks to the Wiki directions, the results look like the factory windshield edges. I'm still pleased with the results and don't regret anything.

Miguel, may I ask how tall you are? And how tall over you the shield was before you cut it down?

I sat on a 300 Super with a tall screen the other day, and the height seemed pretty good for me. I expected it to be way tall, as I'm fairly short. If the GTV screen is about the same height, I don't know if I'd want to cut it or not.

ah, you're talking about a good jigsaw mine cost £20 and has two modes: 'on' and 'off'. I haven't had the Dremel for very long but it only took a short time to realize that i'm much handier with it than i am with the jigsaw.

Miguel - that's a fantastic job you did on your kitchen and stairs! Dave

It called a disk holder. Its primary use is for powersanding turned objects on a lathe but I've used it for all sorts of things. They are available here:

http://www.packardwoodworks.com/Merchant2/merchant.mvc?Screen=CTGY&Store_Code=packard&Category_Code=snding-bholdext-hooklh

They are likely available other places as well. I'm pretty sure Woodcraft will have them if there's one near you. Harbor Frieght may also have them. If they do, they are likely to be the cheapest place.

(NSR: I actually use it up to 4000 grit on furniture pieces, then polish it with three grits of polish. The wood looks like glass. No finish necessary though I often use wax to highlight grain.)

You can use pretty much any disk sander but the advantage of this one is its foam backing. I think pretty much any sander would work. Start with 120 and work down to 80 grit if you need to. Work slowly and keep moving the disk along the end. Don't stay in one place or you'll get a hole. Practice on some scrap from Tap Plastics.
Miguel

I'm 5'10. I think the 300 windshiled is the same as the 250 and is likely the same height as the GTV so, in my opinion, its likely too tall. I'm not sure how tall I'd have to be to look over the top of it like I suggested in the first post on this thread but Its likely well over 6'6". Miguel

Thx. Miguel

I see the shield is after market. Doesn't the headlight reflect off the windshield when the light behind it?

I think it is a GTV with headlight mounted on fender
I not only cut the top off mine but also the sides in order to balance the look..it still protects my hands from the wind and I look just over it.

Exactly right on the GTV. No problem with the light reflecting off the windscreen. In fact, the windscreen for the GTV does not have pocket for the headlight ike the GTS windscreen.

I like the thinner look you got on the hand protectors. WIll ponder that mod.

I noticed you have trim on the WS. I thought about this but didn't do it because it would be right in the line of sight. No problem? Also, wasn't sure I wanted to call attention to the WS that much.

BTW, what is that hanging below the top case?
Miguel

Hola Miguel
That is my wet weather gear it came in a pouch with a belt so I just strap it in between the seat and top box, frees up space, easy access when on tour. If I could have got my edges to a state that would have been accetable to me I would likely take the chrome off, you are right about drawing attention but that was a choice, a little chrome, it does not affect my vision it is lower then my eye and thinner then most. I worried about glare and had the option of using black but I have not had an issue with this either. I damaged the plastic initially so had to cut an extra 20mm off that would have been nice to have. I don't get wind with my open face but it is a little quieter when I duck down 20 mm. Hasta luego

Hi Chazzlee if you have a belt sander, clamp it to a post/wall/bench, belt tuning downwards, you can work your edges smooth fairly easily once you get a rythm going, trick is to keep it moving. Failing that your local glass shop should have a wet upright belt sander, they can turn the water off on that machine and work your edge in a matter of minutes. I am sure if you walked in on the right day with your screen taped around edges to avoid scratches ready to go, through the back door and promised to have your next glass job done by them they would do it for nothing....That machine does a good job because the belt flexes around the edge, the next best thing also at your glass shop is a Makita 1 inch hand held belt sander with the back plate removed so the belt can again flex around your edge. after you sand it it will be milky on the edge. You can get the shinny factory finish by using a small torch on it and heating it. Practice doing this on a piece of your cutoff first, aiming flame away from the rest of the screen, in the wrong hands this could be disastress and not all plastics behave the same way. another way of getting rid of the milkiness is by applying a little oil around the edge but you will have to do this every once in a while as this will wear off, but it is an alternative to heating

Thanks for this detailed information. You said then that it is almost perfect. What would be missing to make it a 10?

Also, your picture looks like the camera was at about your eye level, so that would differ from that wiki article (saying to focus on a spot 25-30 feet forward, on the ground).

I just want to be sure not to cut too much (and do it right the first time).

Thanks

Found this while searching for a windscreen to replace the stock gtv which does nothing. I guess they are charging $23 to cut it down over the $337 standard price on a stock windscreen.

http://cgi.ebay.com/ebaymotors/Original-Vespa-GTV-250-GT-60-Custom-Height-Windscreen-_W0QQcmdZViewItemQQhashZitem3a676cef4cQQitemZ250843295564QQptZMotorcyclesQ5fPartsQ5fAccessories

Your Aaeron chair is stunning!

Hi,
I've just cut-down my windscreen for a gt125.
I'll post some pics soon.
I followed the instruction on the wiki- worked fine.
Some glue residue left after removing the rubber - but so far all else is perfect.

Someone one made a bowling strike in the 2 whelels parking lot, all bikes down,

Juts decided to save the broken windscreen till I found a used tall one at fair price.

Done in 45 minutes and need some finsh care but happy with it.

Nice save, Juju!

You're a genius.

Great work!

One good thing in that situation is you don't have to agonize over messing up a brand new screen.

Lemonade from Lemons! that's great work.

So after reading all the blogs and postings about cutting a full size windscreen, I ordered my full windscreen from Scooter West with the full intention of cutting it to a certain height. It was the Falco brand, 24 in. tall from the top of the headlight.

I installed and drove this full windscreen to see what its like. It was great, no wind to your body and face, and made the ride warmer. The top of the screen fluttered at 40mph. I didn't really care because I will be cutting it anyway. Overall it looked too tall for my Piaggio LT150 and I think it looked weird and dorky.

The Cutting:
Following the suggestion from different blog here in Modern Vespa I proceeded cutting it at where your eyes would see through the windscreen to see ahead 30 - 40 feet ahead on the road. this was about 19 inches from top of the headlight. I even bought the suggested jig saw blade with lots of teeth. My jigsaw did not have an override for rotary cut, so I guess it defaulted to rotary. Halfway through the cut, I stop to reposition myself. When I restarted the jigsaw, it cracked the windscreen. I was able to salvage about 12 inches of the screen. So I trimmed and installed this short 12 in windscreen. It was awfull. The wind was blowing up to your face with such hurricane force and noise. It was out of the question.

NOW WHAT?
I did not want to spend another $135 for a tall windscreen. The midsize screen did not look like it's what I want. So in desperation, I went to Tap Plastic. I figured I could at least fabricate something to see what the right height I really want. I showed the broken sample to the nice guy of Tap Plastic and told him my plan. He suggested a material about the same thickness as the Falco Screen I broke. He said you can hammer on this plastic and it will not break or crack. Great, but it was flat as a wood. I ordered a 24 X 20 piece for $15.
Using the broken piece as a pattern to locate the hole for the bolts and recreate the some similarity to the shape of Falco windscrean including the headlight hole. I carefully drill and cut my Tap Plastic sheet. No problem cutting or drilling. This material was more flexible. After the cut, I ended up with an 18 in windscreen over the headlight. I installed and test drove.
The height was great. It protected my chest and I can feel slight wind on my helmet but the top of the plastic windscreen was flapping really bad because it was so flat. It needed to be curve to make it sturdy.
My son tells me a process his friend use to do. Basically heat up the plastic in the oven and reshape it. Again, no choice, I fired the barbecue grill (my wife was using the oven for cooking) and heat up the top of my new windshield. I practice first using cutting from the big sheet. this is tricky because it would bend at a certain temperature but too much heat and it will get too soft or burn.
I created a slight bend and that fixed the flapping on top of the windscreen. I got so confident in bending this plastic I reshape the bottom part to taper around the handbrake and headlights.

Nice work, Wally. Sometimes the learning curve can be a bit steep....and unforgiving, but looks like it came out well all considered. Glad you could find replacement plastic....the new screen plastic is pricey.

And welcome to MV!