- 1). Determine the size that you want the plastic windshield to be.
- 2). Cover the work surface with a piece of cardboard. You will need to protect the windshield surface from being scratched. You can draw your dimensions with a crayon or grease pencil.
- 3). Mark the line with masking tape. Make sure the masking tape is at least four inches wide. The top of the masking tape should be the mark line where you want to cut. The extra width of masking tape below the cut line will help protect your plastic windshield against scratches. Put masking tape on both sides of the plastic windshield for added protection against scratches.
- 4). Install a fine-toothed blade into your jigsaw. Begin cutting along the masking tape line slowly and evenly.
- 5). Remove the masking tape from both sides.
- 6). Cover or wrap the plastic windshield in a large sheet. You will need to protect the windshield from scratches while you do the sanding.
- 7). Equip a palm sander with 80-grit sandpaper. Begin sanding the cut edges. You can also use a wood block wrapped with 80-grit sandpaper if you want more control over sanding.
- 8). Change the sandpaper to 220 grit and sand the edge one more time. This will provide you with a smooth edge.
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