Step 4: Cut the new Windshield

Trace the template onto the flat sheet of polycarbonate and transfer the alignment mark from Step 3. Cut out windshield using a saber saw on low speed with a wood scrolling blade. It cuts easy, no chips and no cracking. It helps to have an assistant support the lexan well so it does not vibrate or chatter while being cut. Again, be sure to cut on or inside the trace lines so the new windshield is the same size as the old.