Cutting down a windshield

I have an issue looking through slightly curved plastic. For that reason I cut down my driver side double bubble so I could look over it.

With the double bubbles you get good wind flow which is good for summer driving.

For cooler weather a full windshield is better to direct the flow upwards and not into the cockpit.
My SS can with a full windshield that makes me nauseous to look through. I told the dealer to remove it before I took it home. They didn’t want it so I took it with me. It’s been in my downstairs shower stall since.

Today I cut it down so I can look over it. I removed 5 1/4”

I took some pictures of the process.
First I taped it to prevent the jigsaw from scratching it. Then I drew my cut line.

Using a special plexiglass saw blade. You don’t want to cut to slow so the plexi doesn’t stick itself back together from the friction. But you don’t have to race.

Test fit.
After you cut it then you need to smooth the edge off. I used a drill with a sanding disc. First I used 80 grit to knock down any high spots. Holding the disc square to the edge.

This is the factory edge. You need to make the cut edge look like this.

Freshly cut edge.

Then angle it to slightly knock down the corners.
Then I used a sanding block with 150 grit to remove all the marks from the 80 grit.

Then I moved to 220 grit. When your sanding you need to use long strokes lengthwise angling the block over the edge to create a slightly curved edge. You don’t want to create any dips so over lap the sanding strokes do about 8-12 inches at a time. Over lapping each section by at least 4”
I then use 600 grit wet sanding the final pass. This gives you the smooth factory edge.

This is my edge.

Installed. It only took about two hours to tape, mark, cut and sand.