Join Date: Sep 2004
Location: Medford, County of Jackson, Oregon, USA
Model: None at present
I cut down my Cee Bailey about 1" below stock height with a saber saw. Use a plastic cutting blade or a fine tooth wood blade, preferably hollow ground. Don't use a metal cutting blade. Prior to cutting I covered the area that was going to be cut including enough area to keep the foot of the saw from scratching the plastic. Using the saw at a slow speed and with light pressure to keep from melting the plastic which can cause to it grab, make the cut. If you do it with the screen on the bike, make sure you don't let the weight of the say bear sideways on the blade hold it's weight up but keep the saw base tight against the plastic so it won't chatter. It's important to do this in a warm area, if the plastic is cold it will be more brittle than normal.
Once it's cut use a file to smooth the edge. use the file with its long dimension along the edge, not crossways. Once you've got all the saw marks filed out use some fine sand paper, 380 grit wet or dry used wet is a good grade, to polish the edge. The idea is to have it very smooth with no nicks or scratches on the edge which are stress risers and a place for a future crack to start.
None at present
Past 'Wings: GL1100, GL1200, GL1500, GL1800
Current BMW C650GT