On Thu, 4 Aug 2005 08:35:19 -0500, "Jim Burns"
wrote:

While our prop is out for some work, we're putting new 1/4" LP Aero side
windows in the Aztec. A couple of the windows need to be trimmed to fit
properly. What methods have proved to be the most successful? Band saw?
cut off wheel? Any others? We need to take about 1/4" to 3/8" off around
two sides so a belt or upright sander won't work, but I intend on finishing
and beveling the edges once the excess is removed. I understand that we
don't want to use anything that will heat the plastic excessively.

I just finished working with our mechanic on a replacement windshield
for the 172B we just sold.

He used a rasp -- wouldnt use anything powered. We must have gone
through 40 or 50 iterations. We'd fit the windshield in place, mark
it with a dry-erase market, take it off, and I'd brace it while he
took it down a couple of mils. Over and over. (I'd never have the
patience to be and A&P or build a kitplane.)

When it fit perfectly, he buffed the edges smooth with emery cloth and
applied the felt.

Don