I used a jigsaw with fine tooth blade and cleaned it up with belt sander.

 

I've got a jig saw and router, but sounds like the jig saw is the better option along with painters tape or similar. I can only try and see what happens

 

Tape the windshield real good, both sides, and a jig saw is best.
Secret is in the blade, too fine and it melts the plastic that welds back behind the cut.
To course and you take a chance of cracking it, it will jump all over the place.
Go slow, I use a belt sander to clean it up, flame it if you don't like the sanded look.
I use a pen with string to mark my arc on the tape.

 

Cheers Harleycruiser!

 

This is exactly the way I did mine. Once you get comfortable standing position and start cutting just don't stop until you get to the other end.

 

Thanks Lynn, slow and steady right

 

I live near you. Just did one this week. Lexan. variable speed jigsaw, ran kinda slow,fine blade. One thing I'd add. Tape the bottom of saw for extra safety. Sanded by hand. Started with course. worked my way to 800.

 

Thanks for the tip, appreciate it.

 

Make a pratice cut ABOVE or away from the actual line you want to cut. When you get a good feel for it, go to the original line and cut away. YD

 

I fully intend to "practice" before I start chopping into the wind screen