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I replaced my side windows two years ago. I bought the plexi from a local plastics dealer and had them cut rectangular blanks to size. I then sanded the edges with a table sander and fine paper. I used the sander to round the four corners about 1/4 radius and rounded the sliding edge as shown on the microfilm plans. Good directions for working with plexi are available in the LP Aeroplastics catalog. I strongly suggest getting their free catalog. I bought a set of plastic ground drill bits and a reamer from them. I reused the good metal parts and bought some new pieces from Univair for the parts that were worn beyond repair (the upper pieces were worn to a knife edge and were tearing up the welt). Make sure to drill the rivet holes oversize. Also follow the plans carefully. They appear to show the rivets a long way away from the edge but that is to keep the track clear. I used a rivet squeezer and tried not to over squeeze. I made new handles (inside and out) from raw stock because the ones I bought from Skyport were pretty bad (they would work but the workmanship was rotten). The FAR's allow you to do the side windows yourself (and make the parts also if you are the owner) if you sign the work off properly. I also replaced my rear windows from raw stock. I cut them with a $119 home depot band saw. The band saw cut the material to basic shape based on the old windows I removed then I sanded to final shape. David Abrams http://ercoupe.com [EMAIL PROTECTED] wrote: > Any tips on cutting and drilling the plexi? I've heard that the trick > for drilling plexi is to use a dull bit to prevent "grabbing" and > cracking. True? I assume you "cut" plexi by scoring it with a > utility knife and then breaking it? > > Thanks! > > Joa > [EMAIL PROTECTED] > __________________________________________________ To unsubscribe from this list please send mailto:[EMAIL PROTECTED] ___________________________________________________________ T O P I C A http://www.topica.com/t/17 Newsletters, Tips and Discussions on Your Favorite Topics
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