Years ago, I decided to get a custom windshield made for my airplane. Airplane Plastics in Tipp City, Ohio made me a thicker, more-sloped windshield with the same UV protection my canopy has. I went with the thicker windshield to afford some additional birdstrike protection, having been the recipient of a hawk in my face while on a T-38 low-level in west Texas many years ago, a flock of 11 pigeons in an L-39 not long ago, and numerous near-strikes over the years.

My original windshield, which I cut from the canopy, fit the fuselage profile pretty nicely, and I'll keep it in storage in case I need it. But since I'm starting with a new windshield, I have to go through all the fitting and trimming again. Sigh...

1. Used the marks I previously traced using the old windshield to make my first cut about 1/4" from the aft, "canopy bow" line.
2. I then made a cut about 1/2" outside where the factory had made some trim marks for the fuselage interface line.
3. I laid the new windshield in place and checked its fit, making some further trim marks in the places I needed to trim further.
4. Trimmed and deburred the fuselage interface edges.
5. Put the windshield in place and duct-taped it to see where it needed to be trimmed along the roll bar.
6. Made the cut. Sanded and scraped the edges of the glass.
7. Taped the windshield in place again. It's laying down pretty well now.