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Best way to cut a curved windscreen ?

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Posted · Report post

I've got an AMT Dodge Copperhead, that I'm thinking of cutting the windscreen down, old roadster style. Whats the best way to do it, other than very carefully lol.

How do I finish to top edge ?

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Posted · Report post

I use a cutoff wheel in a Dremel, then finish the edge with files and progressively finer and finer grits of sandpaper. You have to plan and mark your cuts carefully, oversize naturally, hold and support the windshield FIRMLY without allowing it to vibrate or flex and crack, use enough speed so as to melt and cut fairly cleanly. The Dremel will make some melted mess on the edges of the cut that will easily snap off with your fingers.

Cutting with a razor saw is usually asking for cracks, as is scoring the clear plastic and attempting to snap it off.

PRACTICE on scrap parts until you get the hang of it...it WILL work very well.

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Posted · Report post

I have done it by covering the winshield front and back with masking tape trimmed trimmed to the edge to protect the glass. Draw your cut line where you like. Use a motor tool at low speed close to your proposed line. Sneak up on the final shape with sandingsticks.

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Posted · Report post

Thanks for the advice guys. I've got a couple of scrap ones to practice on. :)

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Posted · Report post

Eric's tape suggestion is a good one...helps to prevent cracking and protects the clear surface in the event of a slip. I usually live a little more dangerously, sometimes to my detriment.

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