How to Cut Curved Automotive Glass

Written by mary gonzales
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How to Cut Curved Automotive Glass
Cutting curved automotive glass can be done at home. (on reflection image by kenny123 from

Cutting curved automotive glass, to replace a windshield for example, can be done at home. You will only need two special items to get a professional finish to the glass; one is a piece of curved windshield glass and the other is a sandblaster to cut through the glass. Aside from these things a few common materials and tools will get the job done. You should work slowly to get the best results and avoid making mistakes.

Skill level:
Moderately Easy

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Things you need

  • Tracing paper
  • Pencil
  • Scissors
  • Windshield glass
  • Marker
  • Masking tape
  • Aluminium tape
  • Sandblaster
  • 40-grit sandpaper

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  1. 1

    Trace the shape you want your windshield to be onto a large piece of tracing paper with a pencil. Make sure the shape is an exact fit for the windshield opening.

  2. 2

    Cut the shape out with scissors, very carefully staying on the traced lines.

  3. 3

    Trace the template onto the windshield glass with a marker so you can clearly see the line.

  4. 4

    Run a piece of masking tape within the trace outline of the template and cover the masking tape with aluminium tape. These layers of tape will help you keep the cuts on track.

  5. 5

    Cover the area within the traced lines with paper and tape it down to the aluminium tape with masking tape. The paper will protect the glass as you use the sandblaster.

  6. 6

    Make several cuts with a sandblaster into the peripheral parts of glass to meet the edge of the tape. The cuts should be perpendicular to the template rather than running along it. This will help you make an easier cut later.

  7. 7

    Run the sandblaster around the line of tape until all of the waste glass is cut away and you're left with the windshield piece.

  8. 8

    Peel off the tape and paper so you can sand down the edges. Use 40-grit paper to smooth the edges of the windshield.

Tips and warnings

  • Ask at your local hardware store for a sandblaster that can be adjusted, so you can use the setting best suited for your windshield.
  • Always sand glass along the cut line, rather than against it. The cut line is the direction you cut the glass in.

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