How to Cut a Curved Windshield
When customizing a car or truck, it may be necessary to change the size or shape of the windshield. In these cases, a new custom windshield can be ordered through a manufacturer, or the old windshield can be cut to fit. Either option is highly feasible for any project. The first option, obtaining a new custom windshield, is the easiest way for the restorer and may be necessary because of the condition of the old windshield. The second option, cutting the old windshield yourself, is a way to save some money on the project.
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Things You'll Need
- 4 large sheets of poster board or cardboard
- Tape-masking, packaging or duct
- Marker
- Scissors
- Several old blankets
- Glass cutter
- Zippo lighter fluid
- Hand-held torch or matches
- 80-grit sand paper
- Sanding block
Instructions
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1
Properly support the glass to be cut with old blankets or something similar. The glass needs to be supported when it is out of the vehicle to prevent breakage and cracking. Use the blankets to create a cradle for the glass to sit in. Ideally, the entire piece of glass should be supported by the blankets.
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2
Tape posterboard sheets together to create a panel larger than the windshield mounting location. The posterboard should be taped on both sides with at least a 2-inch overlap. Strength of the board is not as important as flexibility.
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3
Place the posterboard over the hole for the new windshield and tape in place.
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4
Trace the opening from the inside of the vehicle with the marker as close to the edge as possible.
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5
Remove the posterboard and cut out the traced shape 1/2 inch larger than the traced line. Make sure to cut the template larger than the mounting location in order to be able to remove material to make a proper fit. Material can always be removed, but it can't be added.
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Test fit this template in the mounting location. Trim the posterboard until the template fits properly.
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7
Place the template on the glass to be cut and trace with a marker. The template should be placed along the bottom edge of the glass to be cut. This willl help to reduce the number of cuts needed. Remove the template when done tracing.
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8
Score the glass along the trace lines with a glass cutter. Use enough pressure to create a scratch on the surface of the glass. Glass is a brittle material that breaks easily. Use the least amount of pressure to create the scratch. Do not attempt to cut through the glass.
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9
Turn the glass over and score the other side along the same line.
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10
Lightly tap the glass along the score lines on both sides with the glass cutter to crack the glass along the score lines. The glass may break free at this point if it is not windshield glass.
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11
Squirt a line of lighter fluid along the score line on one side and light with a torch or matches. This will melt the plastic core to safety glass and finish the cut.
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12
Test fit the glass.
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13
Sand the glass edges with 80 grit paper to smooth and adjust the fit.
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Tips & Warnings
Make sure to properly support the glass before attempting to cut.
The lighter fluid can be replaced with rubbing alcohol.
Cut glass is extremely sharp--use caution when handling.
Make sure to sand the glass along the cut and not across the surface of the glass.
