Looking for tips on cutting out door windows

[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.