I'm looking for some how-to information on "cutting" down or "chopping" a windscreen. I have a 67 Spitfire that I need to cut down the windscreen to approximately 7" wide. I know it can be done, just don't know how its done. I've contacted the local glass shop and they said they could try it but they can't guarantee that it won't crack. Anyone with any experience doing this?
Somebody on here recently said the way to go was to put several layers of duct tape on the windshield, trim out the pattern and then use a sandblaster to cut along the edge.
And that is one cool Spitfire speedster! 
I'd call that 7" tall.
When I did my Spridget, I used Lexan.
Yes, having thought about it, it appears that lexan or plexiglass is the best way to go. How did you cut, heat and mold the lexan? I've never worked with lexan but I would imagine a 7" x 44" (approx) strip of lexan would be fairly flexible piece to work with to get into the right shape etc.
That Spit does have the cool factor going for it. Other than the swoopy windscreen, I couldn't quite put my finger on why it looked more aero than other Spits then I realized it didn't have front bumpers/over riders making it more slick in appearance. Also there doesn't appear to be a rear package shelf on this particular model (Spitfire4 MkII).
Suddenly I want a Spitfire.
One of those early reality car build shows showed a guy modifying an original windshield by using a glass cutter on both sides at the cut line then pouring alcohol (rubbing type, not booze) on the crak, lighting it on fire to melt the plastic core and breaking it along the cut seam. It might work, but I think I would get a junk yard windshield to practice on before I commited to using the one I had for the project.
I am planning on using polycarbonate in my project. To make it strong enough to run nearly edgeless, I am going to bond 2 layers together, which should help it hold the shape when bonded on a form.
Steve Stafford
I think I have just found what I want my 64 to look like when it gets done.
stafford1500 wrote: One of those early reality car build shows showed a guy modifying an original windshield by using a glass cutter on both sides at the cut line then pouring alcohol (rubbing type, not booze) on the crak, lighting it on fire to melt the plastic core and breaking it along the cut seam.
This is the traditional method, but I read more and more about using a sandblaster to make the cut instead. If you google on 'how to cut a windshield' a number of hits come up, some with video.
The guys at the glass shop said they will score both sides of the WS with a a glass cutter, then break it along the cut. Want to charge $150 and its at my own risk. I think I'll probably just do it myself. The windshield is pretty scratched at the top anyway so don't really have nothing to lose. They don't do lexan and basically told me about the many issues I would have with it (scratches, poor sealing in frame).
Do you have any businesses that do waterjet cutting in your area? They should be able to cut the windshield fairly easily with minimal risk of damage, and have the cut edges be nice and straight. It will probably be more expensive than the sandblaster method though.
Bob
Curmudgeon wrote: Somebody on here recently said the way to go was to put several layers of duct tape on the windshield, trim out the pattern and then use a sandblaster to cut along the edge. And that is one cool Spitfire speedster!
My business partner has been in and around the glass business for 30 years. According to him, this is the only way to do it safely. The score and burn method only works with nearly flat pieces of glass. Use at least 10 layers of tape, and plan on replacing it.
Lexan is as easy to cut as plywood, sands well with a power sander too. I wouldn't trust adhesive to hold it in the frame alone, but augmented with machine screws it will hold and seal.
It is flexible enough for gradual arches, and can be heated and bent for tighter bends.
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