This week was about finishing the rear windows and starting on the windscreen.
The process for the rear windows is about first getting close to the scribe line with a Dremel tool. Then using 120 grit sanding belt before hand shaving closer with 220 and polishing/rounding the edges with 320 grit.
For the windscreen first peel back the protective covering just enough to expose the previously marked scribe line.
The windscreen is a slightly different process, as it is much thicker (roughly 1/4″ Lexan or acrylic). My technical counselor advised against using a Dremel tool, saw or other cutting mechanisms (tend to cause cracking in this type/thickness material). Instead a 3″ belt sander with 80 grit paper is used to get close. Everything else is by hand.
When talking about ‘by hand’, I mean hours of edge sanding with 80 grit paper on a Great Planes sanding block. Going through Lexan this thick takes time. Check for fit, mark the high spots, and repeat over, and over, and over…
The hand shaping process requires many iterations, but this way has less danger of removing too much, too fast in the wrong places as with power tools. The final outcome is coming into shape nicely. More of the same fitting process this weekend before the edge polishing can begin.