That sure is impressive. Don't know if I would have the patience to do that job without screwing it up.

 

Stu, that's the way the old school guys did it, with the exception you left off one step: after scoring you have to crack the glass on both sides. Safety glass is soft glass like standard window glass so it will crack along a score with tapping just like cutting a new window for your house. After both sides are cracked you can melt the plastic center with the burning alcohol trick.
The other secret to doing it this way is to only attempt it on a new unscratched windshield, any scratches risks it cracking during the cutting. There is a glass shop down the street from me where the old owner cut glass for hotrods and customs regularly. Unfortunately the guy died about 5 or so years ago, and the new owners won't touch anything but flat window glass.

 

Yup, I left that step out. Watching the guy do it, it sure was painless. Stu

 

I really didn't think there would be much response to this. Kinda surprising.

 

Superb job, you are the man.

 

Drew,
Great tip and job. Hope the new windshield turns out that nice for ya

 

Guys the windshield does look good. I spent about 1.5 hour over to Andrews place this afternoon. Drew as 983 allows I will get back over soon so we can look at a latch for my fuse block..

 

Nice! Makes me want to do a big chop top on my truck.

 

Nice work! Smart to try it on an old windshield....

 

There is a distinct lack of beer cans in the images.... not true red neck engineering!

 

You can trim up your cut with a belt sander with a 120 grit carbide grit belt. Run the sander at about a 30* angle to the edge, keep it moving with long strokes and light pressure so's not to heat up the glass.