Cutting plexiglass windshields?

XJers:

Anybody have any experience cutting plexiglass windshields?

I am considering buying a used fairing, and was wondering if the bottom inch or two of the windshield could be cut off, new mounting holes drilled, etc.

I was thinking I would put duct tape on both sides, then use a fine tooth blade in a jig saw.

Think it would work?

Thanks,
mhhpartner

 

I cut my windshield down using a sabre saw. I tried a fine tooth blade, but it got too hot and the windshield would melt together right behind the cut. so I tried a course tooth blade and it seemed to work pretty good. I used 2" wide masking tape (a couple layers" on both sides of the windshield to mark exactly where to cut. After cutting, I used a fine file to take off the big marks, then went with 100 grit sand paper. Then I went with 400 grit sand paper, then to the buffer to smooth out the edges. It turned out like new.
You have to be careful when cutting with the saw, because some windshields are made of more brittle material then others and will shatter if the saw takes too much of a bite. Take your time and cut slow and you should be alright.
If you have access to a belt sander, you will be in business for finishing off the rough edges, before buffing it smooth.
I've cut several windshields using this method and it seems to work fine for me. Good luck!

 

Thanks for the info and tips, PD!

I figured someone had done it, and feel a lot more comfortable after hearing some actual words of experience.

Thanks again-
MHHPartner

 

We had a plexiglass windshield cut down at a place that engraves trophys with a laser. They used the laser to cut where we had the windshield marked and taped. It left the edges rough so my husband sanded it and it works great.

 

An electric or air driven dremel with the side cutting bit works very slick and fast. Just wear eye protection. You can mark the line you want to cut an follow it pretty easily with a dremel.

 

XJers:

As always, you've come through with great tips and advice.

Many thanks!

MHHPartner

 

XJers:

As always, you've come through with great tips and advice.

Many thanks!

MHHPartner