| Richard, that clip comes out with effort. There is no good way to grip it, so you'll wind up dinging it a little. I used a sharp edged screwdriver and mallet and I place the screwdriver point next to the split and tapped toward the center of the pane, catching the clip with the sharp edge and forcing it to slipe along the surface of the plexiglass.
Stone Ridge, yes, I'll use butyl. I'm working on determining whether 0.25" thick will make the total panel too thick (by about 0.03"). The alternative is to use what the glass folks call pre-shimmed butyl, which has a rubber cord in it. There is version that is 0.215" thick, which would make a panel about 0.01" undersized.
The "plugs" you see are a method of providing that pre-shimming action to maintain a consistent butyl thickness as you press the glass panes together.
The gray U-shaped gasket material is available, but I need to find a shop who will sell one roll of it, rather than the minium order of 8 rolls from the wholesaler. More news on this next week.
Zep
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