Like the windshield, we used a "prototype" for the Lexan door window.

It was a little tricky figuring out how the "prototyped" window fit into the door frame. The window needs to bend with the door frame.

We cut the window to fit pretty well, then drilled just a few holes. Then we refitted and trimmed a few times.

A - Notice on the bottom of the photo that there is about a 3" overhang of the 'window'. The hinge will be joined to that overhang. We will end up trimming off much of that overhang, but having the excess helped us install the hinge - see the next page "Fitting the Door".

B - Also note the wood block used to make the clamp conform to the door shell curvature.

Extra photo.

We found we could control the amount of trim by using a large aluminum planing file. This file is available from Avery. We used masking tape to identify the filing edge. Then we just filed to the tape.

We layed masking tape along the hole line so we could set marks for drilling.

First we determined how far from the edge we needed to drill. We measured the distance from the edge in two locations, then drew a line between those points. BE CAREFUL! On two sides, there is very little room. The hole needs to be centered so you do not drill off either edge (the window or the door frame).

Then we labeled a few 1 1/2 inch holes and used our pre-drilled ruler for drilling.