I made a non-permanent windscreen for Studio Series 86 battle damaged Ironhide (and another for yet-to-be obtained Ratchet). I wanted to keep him in vehicle mode, since the SS86 normal Ironhide has no yellow stripe in vehicle mode.
1. Using normal paper, I placed it on the windscreen and rubbed pencil over the borders to mark the outline.
2. I cut this out and placed it over the windscreen. I trimmed it closer to the right shape and size.
3. When it wasn't right, I used that prototype as a template for another piece. After repeating the process, I got the piece of paper the right size and shape. The corners were trimmed without needing to mark them and the notch for the wiper I marked with pencil and cut that out. I used a pair of fine scissors.
4. I spray painted it light blue.
5. I cut a piece of scrap spongy foam to fit the blast effect hole and cut it to the right height, then put a small piece of double-sided sticky tape on the foam with it sitting in the hole. This allowed me to attach the foam to the paper at the correct location - lining up the paper to the windscreen.
Now Ironhide can join the party!