Getting cold feet on Trimming the windshield

[Sierra Skydog]

Fitting up the windshield. Looks like I need to cut about 3/4” off the straight edge where it fits into the top channel for the best fit. What is the best method for this cut? Was thinking of using a thin steel-cutting blade in an angle grinder but want to be sure before attacking this pricey piece.

[jaredyates]

That is what I would use. Make yourself comfortable and well supported.

[BTAZ]

Worked for me as well. I used a thin abrasive metal cutoff wheel in an angle grinder as well. Worked great, makes a mess, slightly melts the edge(which is probably why no cracking in the process) so there is an easy burr to remove.

[Sierra Skydog]

Good to know! That’s reassuring and I will give it a go tomorrow. Thanks for the quick replies! Once again the forum comes through

[gregc]

I found that every adjustment changes the fit somewhere else so you may want to do it in multiple small steps.

[BTAZ]

Make sure you have a steady hand to follow the line and don't let the grinder catch and skip off. It has been a few years and I didn't have any problem but I don't know how much experience you have with an angle grinder. It does make a mess and throws slightly melted plastic snow everywhere but also cuts trouble free with the appropriate care and control. IIRC I also used a pneumatic cutoff tool as well(uses a smaller abrasive disc and is lighter in the hand so easier to control) which gave good results as well.

[Pbruce]

Same here: thin cutoff wheel in a grinder. I went in small steps and it went ok. Then I used a belt sander and finally some sandpaper to smooth the edges a bit. I needed someone to hold the windshield for belt sanding.

I did damage the windshield (by clipping it with another part while stowing it) but was able to fix it. You are right to consider everything carefully. I looked into a replacement and it was $500 to buy and another $500 to ship.

[alaskabearhawk]

Like the others, thin cutoff wheel and patience. You can replace the cutoff wheel with a maroon 3M roloc pad and clean up the edge.

[Ryan Koeneke]

I've been using routers to cut aluminum sheet, acrylic, and polycarbonate. It probably makes as much/more of a mess but gives the option for dust collection to avoid the mess. I also think its more controllable and gives a better finished edge on the material being cut then what I've done with angle grinders (but maybe i'm just using the right router bit and the wrong angle grinder blade. (I think the correct router bit is a 1/8 o-flute specifically this one: https://www.shapertools.com/en-us/st...ute-router-bit)).

All that being said, I haven't trimmed the windshield just yet...

[alaskabearhawk]

From LP Aero: https://lpaero.com/trimming/

[Battson]

Worked for me as well. I used a thin abrasive metal cutoff wheel in an angle grinder as well. Worked great, makes a mess, slightly melts the edge(which is probably why no cracking in the process) so there is an easy burr to remove.

I agree - melty is good, hard to crack a liquid. Fast cutting speeds.

I don't think cutting is a "must do" any more, there is usually a way around it. The plastic doesn't have to fit perfectly, you can use fairings and silicon sealant to cover any gaps.

[Bcone1381]

Another view. I followed the LPAero document that Alaska shaerd in Post #10.

I used the angle grinder with and 80 grit "flapper" abrasive disc. I would draw my line then remove the material. It goes real quick. Like 30 seconds to remove an 1/8" off one side. It was Easy to make small changes. When the trimming was completed, I radiused the edges with maybe 220 grit sand paper to remove all stress risers.

[svyolo]

I will 2nd the flapper disk. I used one as well.