Cutting a PlexiGlass windshield
Cruiser
Joined: Jun 2006
Posts: 197
Likes: 23
From: Edmonds Wa
Use a saber saw w/tape on the base, secure plex, hold saw to keep from bouncing. Take fall down piece of plex to practice on, sand edges from medium to fine taking sharp edges off, you are done when edge is smooth and a even frosted color . Use a propane torch and pass over the edge w/flame slowing down each time ( this will show you how warm the edge needs to get with out damage ). You are done when edges turn clear they will have a slight radius and will be less likely to crack from stress. You can also use a heat gun, I mostly use a torch cause its faster. Have fun doing it.
Seasoned HDF Member
Joined: Jun 2015
Posts: 10,284
Likes: 7,766
From: West Central FL
If this is your first time cutting a windhield and you're not really good with a cutting wheel on a grinder you will destroy the windshield. Personally I use a saber saw with a fine metal cutting blade.
First I lay on a double layer of Duct Tape across the surface that the saw will run on then I mark out a cut line that matches the existing curve of the windshield only lower. I make my cut then clean up the edge with a sanding block and when I have it right I remove the tape and dress up the outer edges with an emory board. The saber saw is a lot easier to control then a cutting wheel.
First I lay on a double layer of Duct Tape across the surface that the saw will run on then I mark out a cut line that matches the existing curve of the windshield only lower. I make my cut then clean up the edge with a sanding block and when I have it right I remove the tape and dress up the outer edges with an emory board. The saber saw is a lot easier to control then a cutting wheel.
Ultimate HDF Member
Joined: Oct 2010
Posts: 5,456
Likes: 2,860
From: SW FL-Jersey Shore Emigre
I've cut down two windshields, and they came out looking like factory. Use a JIGSAW, not a Dremel, lots of blue masking tape, etc.
There are a number of videos on YouTube on how to mark, cut, and finish a Plexi windshield. Check them out!
There are a number of videos on YouTube on how to mark, cut, and finish a Plexi windshield. Check them out!
Road Warrior
Joined: May 2013
Posts: 1,486
Likes: 619
From: North Dakota & Minnesota
Seasoned HDF Member
Joined: Feb 2011
Posts: 6,185
Likes: 4,115
From: Michigan
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Extreme HDF Member
Joined: Sep 2008
Posts: 15,259
Likes: 5,383
From: Delaware
Just another vote, from experience, with a jigsaw and masking tape. I layered the tape out so it was wide enough to ensure the saw base would always be on the tape and not the windshield. Mark your cut line on the tape. Keep the saw base tight to the surface and slowly trace your cut line. I hand sanded the final cut with 100 them 500, then 2000 grit paper. Probably over kill, but I was able to put a nice rolled edge on the cut, much like the original shield.
Tourer
Joined: Feb 2017
Posts: 280
Likes: 79
From: Tennessee
Use a fine blade lots of tape and clean up the edges with fine sand paper like 320 or 400 grit. Or take it to a local glass shop might cost a few dollars but you know your not gonna butcher up your windshield