[BDR_Boy]

Okay... finally had time to create a template.

I established the centerline of the windshield & drew a line across same and out onto the poster board. I then secured the windshield to the poster board at these two points of reference using blue painter's tape. I then rolled the windshield each direction on the flat poster board & used a Sharpie fine point permanent marker to trace the outline. When I cut it out... I cut along the outside edge of the marker line.

The template is close... and... predictably... appears to be the width of the marker larger all the way around. It isn't much.

When I initially removed the frame from the windshield... I noticed that some portions of the windshield sat deeper into the frame than others. Most notably... the upper corners weren't in as deep.

My next question before having the Lexan cut...

Am I better off trimming away that marker line from the template to get it closer to the actual size of the windshield... or is it better to have it cut slightly larger and then... IF it requires trimming... I'm assuming that could be carefully done with a Dremel tool?

Experience... and thoughts coming from experience... are appreciated.