I started installing the window glass today. Everything always takes longer than I expect, and this was no exception. First, I laid out the rivet pattern on each leg of the door. Then I used my auto punch to set the drill dimples, drilled the #40 holes and cleaned them up. Then I cut out a ruff shape of polycarbonate and clamped it to the frame. I then used a #40 hole finder to match drill through the polycarbonate and cleco it to the frame.
Then I match drilled to #30 size and cleco'd to the frame.
Last, I marked and trimmed the sides to final size. There is still some trimming/sanding to do on the top and front edges. The top edge needs to be sanded to final shape just above the clecos. The front edge still hits the shock towards the bottom of the window. Finally, all the corners need to be rounded off.
