Cutting assembly for removing a windshield and method relating to same

A method for removing a windshield made of glass from a vehicle wherein said windshield is attached to the vehicle using a urethane bed, the method consisting essentially of:

• providing a tool assembly comprising:
• providing a reciprocating air gun being operative to longitudinally reciprocate a shaft and a steel blade with sufficient force to advance a front edge of said blade through the urethane bed;
• providing the shaft having inner and outer ends, the shaft connected at its inner end with the air gun for reciprocation thereby, wherein the shaft is rigid and elongated, the shaft being operative to space the blade from the gun sufficiently to allow the assembly to be used within the confines of a narrowing apex space between the windshield and the vehicle, the outer end of the shaft including a slot for receiving a shank of the blade, the outer end also including a recess on a first side of the shaft, the outer end further including bolt holes passing transversely from a second side of the shaft to the first side of the shaft and intersecting the slot and the recess, the bolt holes having a countersunk portion on the second side of the shaft, the bolt holes aligned along a longitudinal axis of the shaft;
• providing the blade, wherein said blade is made of stainless steel, and is flat and thin with a thickness of about 0.05 inches, the front edge of the blade located opposite the shank of the blade, the blade being substantially coplanar with the shaft with the shank of the blade inserted within the slot in the shaft, the front edge of the blade being substantially straight and beveled on one side only to provide a non-sharpened top edge and a sharpened bottom cutting edge, the blade narrowing from its front edge width of about 4 inches to its shank, wherein said front edge is wider than the width of the shank of the blade and wider than the width of the shaft, and wherein there are no significant lateral protuberances of the blade at a connection between the blade and the shaft, the blade being sufficiently rigid to cut the urethane bed when reciprocated by the air gun but having sufficient lateral flexibility to conform to a curved surface of the windshield when pressed against the windshield, the blade being configured so that the non-sharpened top edge of the blade can be pressed against the windshield while the sharpened bottom cutting edge penetrates the urethane bed;
• providing a first bolt and a first nut sized to be tightened on said first bolt, and a second bolt and a second nut sized to be tightened on said second bolt, the first and second bolts having head portions that are sized to be received within the countersunk portion of the bolt holes in the second side of the shaft, wherein the bolt holes and the recess allow for insertion of the first bolt and the second bolt in the bolt holes to secure the blade within the slot of the shaft, the first nut and second nut positioned within the recess in the shank, whereby the countersunk portion of the bolt holes and recess prevent the head portions of the bolts and the first and second nuts from extending beyond a circumference of the shaft, and thereby further prevent the bolt head and the nuts from scratching a dash or an interior portion of the vehicle;
• placing the blade against the urethane bed such that the non-sharpened top edge is against the glass of the windshield;
• forcing the front edge of the blade against the curved surface of the windshield to conform to the curved surface of the windshield by applying pressure to the gun, thereby laterally bending the front edge of the blade to conform to the glass of the windshield;
• driving the front edge of the blade through the urethane bed by triggering the air gun to reciprocate the blade longitudinally into and out of the urethane bed;
• moving the blade progressively around the remaining portion of the urethane bed so as to cut the entire urethane bed;
• and
• removing said windshield from said vehicle by separating said windshield from said vehicle;
• whereby said placing, forcing, driving, moving, and removing steps are capable of being performed in less than about 3 minutes, regardless of the size of the windshield.