Looking for tips on cutting out door windows

[Grant4ever]

I'd be concerned about the spraypaint giving you a false hole center if not applied perfectly straight into the hole.

I'd also be concerned about any getting under the film edge and becoming an issue.

If the original windows were done correctly, the holes should be 5/32" final size. Using those holes as a guide will require the same size bit to stay as accurate as possible.

[Grant4ever]

Remember, the holes in the door frame should be 1/8". The final sized holes in the Lexan should be 5/32".

[GMKman]

Just re done my doors 2weeks ago and used Wiss tin snips to cut all edges and then used a block sander to finish edges. I had the old ones for templates but left all edges long until they were fully riveted on the frames concerned that all of the curves and bends could distort the straight lines if not mounted perfect.
After mounting doors back on my plane, I peeled back film and used the door opening to mark and trim to fit perfect.

[jtpitkin06]

Bandsaw - fine tooth metal cutting blade. With 32 tpi or more. Stay 1/8 to 1/4 inch outside line.
Finish edge with electric sander. I used a belt sander with 180 grit.

[Floog]

Harbor Freight pneumatic 'body saw' with fine tooth metal cutting blade.
Blue taped the glass, drew the line and cut to the outside edge of it.
Finished with block sander. Violla!

[beeryboats]

Thanks for all the info. I guess there's more than one way to skin a cat as they say. One thing that still has me scratching my head is there are small cut-outs about an inch in diameter where the door hing bolts are located. It's too tight a radius to cut with a band saw. What about a router? Too high speed? Or a router bit in a Dremel?

[efwd]

If your talking about notching out the acrylic I will say you could make short work of it by using a course grit sanding discs on a Dremel. Mark your line and go to work. It will cut through quickly.
Eddie

[t j]

For door hinge cut-outs in Lexan, a Dremel sanding drum would work well. To make the holes to insert and remove the front spar pins a unibit works well to.

[Slyfox]

call me a guy that goes against the grain. ha, I use a jig saw all the time on these lexan windows. I just did my front screen. But, you need to get the finest blade you can, for metal. OR your screwed. That is all. for now.

oh , keep your protective covers on until the end. when cutting, make your cuts as close to the bench as possible, prevents the window from getting too much slack, that can be bad.

[t j]

I cut out my last windshield skylight with a hacksaw. Then finished the edges with a file first, then 60 grit sand paper, then 120, then 300 then 400.