I need to trim about 2-3 inches from the rounded part that goes over the headlamp, thinking of using my dremel tool to grind it off, has anyone done this or is there an easier way without cracking it? thanks

 

When i cut my windshield down, i used painters tape and a jigsaw. You can check youtube for videos. Should be easy, without cracking.

 

The best thing for cutting plastic in a home shop is a spiral saw, like this one:

http://www.homedepot.com/p/Rotozip-R...5-10/203408190

 

Agreed. I've done many myself this way, works perfect every time. Then I take a sanding block and wet-sand with 400 grit wet/dry sand paper to smooth and even up the edge. Then follow that with 900 grit wet/dry and you'll have a smooth factory edge. It really is simple to do.

 

Use a Roto-zip tool if you can. It operates like a small router and at a much higher velocity than a Dremel so there will be less of a chance of cracking and breakage.

 

Plus one on the painters tape and jig saw. I just cut my windshield down last week. (Edge of the shield was right in my line of sight with the new seat) Used a file to clean up the saw marks, 400 grit paper to smooth it out, then steel wool for that factory smooth finish. Looks better than downtown.

 

Jigsaw here also.

I left a little material and thought i would sand it back to where I wanted it, but it is just soo much easier to cut it where you want it and do less sanding.

I take a torch to mine and make the white edge clear again, but you have to move fast!

 

I've done 2 with a dremel and a milling bit. It works, it's not easy to control so the line will be jagged, so you also need a table top belt sander to clean it up, then you can wet sand it with fine grit to polish it. I don't know what you'd do with out a flat belt sander. I guess a sanding block or file would work, it just would take a lot longer.

 

Thanks for all the feedback!