Link to willg's Windshield Building Thread!willg wrote: ↑Fri Sep 15, 2017 9:23 pmI thought I'd show some pics and document my windshield fabrication. After looking into this online I figured there could always be a little more info available. This is .22" plexiglass from HDepot. I had enough material from one sheet to make 2 windshields. I first used heavy paper to make a template on my console to get the gist of what I wanted, then transferred it to a piece of ply to make a permanent template. I didn't worry much about exact measurements for the template, just made sure it was symmetric. I transferred the template pattern to the plexiglass, but drew it wide so I could rough cut the plexiglass on the table saw. Then I taped the plexiglass to the template and ran it on the router table using a straight pattern-following bit. The router does a clean job on the plexiglass (the table saw does not). I then rounded the edges on both sides with a 1/4" roundover bit. I then flame polished the edge with a MAP torch (also HDepot). This turned out nice. I used the console itself as the bending form for the corners. After slowly heating the bend line with a hot air gun I taped it to the console, did the bend and held it till it set. It's hot as hell and you need gloves for this! Despite all the warnings about drilling plexiglass, I drilled the holes carefully beginning with little bits and worked my way up - no problem. It was attached with finish washers and rubber washers.
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