I cut mine a few inches shorter after I ran over something that took a big chunk out of it. I think I was inspired by how Thomas Alberti had cut down his. I prefer having some protection from getting gunk all over the shock and spring.
draw a line where you want to cut it, the curve of the hugger shuold allow you to use a hack saw. maybe scor along the line first before yoou cut all the way throu. if you find a spot where you can't finish the cut with the hacksaw, try a razor knife where previously scored with your hacksaw. than file, or sand the ruff edges.
If you're really patient, you could draw a line on it where you want to cut, then run a really sharp knife or a single edged razor blade around the line. Then trace over it again 40 or 50 times, applying a bit more pressure each time. Eventually you'll cut through the plastic, and if you've been careful, you'll have a nice smooth edge.
I used sand paper to smooth out my edge once it was cut.
when i hacked my airbox lid (same material as the plastic rear hugger), i used a dremel with a cut-off wheel. it did more melting than cutting and was a real messy result. i dunno... some people say they've had good results but i got fed up. i wound up using a jigsaw and was surprised by how clean and smooth a cut it resulted in. sand smooth as scott mentioned and you're good to go.
for a CARBON hugger, i'd say use a dremel. taking a jigsaw to carbon's prolly a real bad idea. also remember if you're cutting carbon to wear a mask. the dust is bad for you. correction... the dust is _BAD_ for you.
I used a jig saw to cut my front fender for the main cut, cleaned up with a razor blade & a file. Should work the same for the hugger. First thing I did was to put down some masking tape and drew my cut. Cut with the jig maybe 1/4 in from line then took off remaining with a nice & sharp razor blade. I could have done a better job - but the process seems to be valid.
I just trimmed down my rear hugger last night (I was inspired by this thread!) I used a 4 1/2 inch angle grinder, a file, and some fine sand paper for the job and it came out looking really nice. I also masked with tape, then cut with a cutoff wheel on the grinder. I then switched a grinding wheel to get the shape and bevel perfect, used the file for the tight spots, and sand paper for a smooth finish. The grinder worked great - very fast and no melting problems. The whole job took me about half an hour. I think tonight I might revise the shape a little (If only because that grinder is so fun to use!). Digi camera is coming soon, so maybe I can get some pics.
I didn't spend much time on this at all. Eyeballed a pencil line on the hugger-pencil is nice cause it's shiny and easy to see but comes off easy leaving no marks. Cut with a jigsaw using a multiblade-small teeth. Sanded for a second or two with a palm sander. Longest part was plugging in the extension cord! I'll snap a pic tomorrow.
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