Chopped Shoebox Ford Windshield Questions - Educate Me

This is my first chop. I have quite a few questions about the windshield.

How do you make the template for the new gl***?
What material do you use?
How much space do you leave around the edge, and down the middle?
Who makes the best seal?
How do you modify the seal for the new gl***?
Where do you make the cuts?

Any help would be appreciated.

Thanks,
Rich

 

Anybody out there?

 

Rich,I can't help with all the questions but we use heavy poster/construction board to make the for templates then transfer to thin plywood.

We try to leave about 3/16" play all around.

We always cut about half way on the sides and glue it together. HRP

 

I think I'd see how the original gl*** fit in the original hole and cut it until it fits in the new hole just like the old hole.

I'd probably make a pattern out of masonite.

 

^^^^That's how I did mine worked great. Got my gasket from Dennis Carpenter payed close attention to how the original gl*** fit (you can usually tell where the gasket was by looking around the edges). Then I chopped the top and fit the gasket. Made a template from masonite. I used new windshield gl*** for a stock car. Then cut and polished. If you google cutting shoebox gl*** and include hamb in your search a few threads come up. Good luck