Acrylic Windshields are tough - BUT
THEY ARE NOT UNBREAKABLE - use care in handling and working
A Band saw it the most common way to trim the
edges of aircraft Windshields. Use a blade with at least 24 teeth per inch
and a high speed - about the same speed as is used for wood.
DO NOT use reciprocating saws, such as
A high speed router may be used for trimming,
however, a fixture guide or a very steady hand is required to use this
To remove smaller amounts from the edge, generally
1/8 inch or less, a hand held disk sander may be used. A medium grit paper,
and very light pressure on the disk sander produces good results. A belt
sander may be used.
Hand tools, such as files, hand saws, sandpaper
may be used. Be careful, any binding of saws or files may cause breakage.
Before installing the Windshield, carefully smooth
the edges to remove notches. Acrylics are notch sensitive
Any drilling must be done with drills that are especially
sharpened for the purpose. See drawing