Thanks for the replies, sounds like I can use either 3/8" or 1/4". I'm going with 3/8" (9mm) for the extra strength and so it will be flush with the exterior hull surface. The actual sizes from Acrylite are in mm, I just measured in inches out of habit.
I have one window pulled now (it came out quite easily, fortunately, after thrubolts were removed). The prep / cleanup looks like it's going to take a long time, as expected but maybe a bit worse than expected. This plexus stuff is a *pain*. On the surface closest to the old window was a black rubbery sealant, which comes off easily, but below that is some kind of black / brown hard epoxy. >From prior threads ( http://cnc-list.com/pipermail/cnc-list_cnc-list.com/2015-February/073099.html ) I understand this is a methacrylate adhesive, aka Plexus (the brand name). Robert H in the prior thread decided to just fair over it, which I may have to do as well in some places. Another thread that discusses the Plexus headache is by Gary Russell - http://cnc-list.com/pipermail/cnc-list_cnc-list.com/2015-December/080369.html His experience was a bit different though (he had a very hard time separating the old acrylic from the Plexus), which makes me think maybe our windows have been previously replaced, and a sealant was used on top of the Plexus. It sounds like he used a router or RotoZip to cut off the plexus. We shall see (this will take a while). -Patrick
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