For those who've used a router/dremel for stack/vista views...

[Taylormade]

1. Did you use a template like described in this tutorial?

It occurs to me that, if you use a bushing guide in your router, it will eliminate the need for a template. The template is there so the bearing on the router bit will have something to ride against, but if I use a 3/8" guide bushing and a 1/4" straight bit, it should act in the same fashion.

2. Did you have to use a bit extender to reach? My inner skins are on still which gives me the ability to use the trim ring as the template. Problem is that my bit won't reach the glass, let alone go through it, as is. I don't have a bit extender but can pick one up at Woodcraft today.

3. Did you remove the remaining acrylic and butyl and reseal or just leave well enough alone (assuming there's no leaks)?

4. If you removed/resealed, what did you reseal with?

My intent is to leave the inner butyl and acrylic (please please please be acrylic) ring in tact and just sand the rough edges the router leaves and call it a day. A glorious wonderful day.

5. What are the chances I can get through this without breaking any of the 6 windows?

[Taylormade]

I should say that I'm talking about the stack windows that are too "deep" to be hit by the router bit and not the vistas. The VV windows look like they're able to be cut... I may give them a whirl in a bit.

[Bill M.]

Never done vista windows. Use a router quite a bit. You need the template. Gives the router a flat smooth surface to slide on. Gives a solid, smooth guide surface to the bearing or bushing. Yes, you could use a straight bit in a bushing and guide the bushing with the template. But you still need the template.

[Taylormade]

Thanks for the reply Bill. In the example provided in the link above, I'd agree that it's necessary, but I still have my interior skins on, so there is a flat smooth surface to attach to. There are some rivets to go over, but truthfully I could drill them out and replace them a lot easier than building a template and cleaning up the mess from double sided tape. That's for the stacks at least.

On the vista's yeah, we're talking a different animal entirely. They're curved and the "lids", for lack of a better word, are in the way.

I'll give the vistas a shot in the morning and see how it turns out. Wish me luck (and no broken glass)!

[Taylormade]

Well we can disregard this thread. Turns out it's not acrylic and it's safety glass in my stack windows. I ended up taping and smashing them this morning.

Does anyone know if the vistas are for sure acrylic or is there a chance they're glass as well?

[desertair27]

My 77 Soveriegn windows are all glass. How difficult was it to break the glass in the stack windows? Can you post pictures of your work?

[Taylormade]

Honestly, I had to beat the living daylights out of each window in order for them to break. I was terrified I was going to go through both panes.

I actually took a ton of pics and will start a new thread for all to see.

[CanoeStream]

All windows are safety glass unless repaired/replaced with Lexan. I'd think 20 or more year-old Lexan would look kinda funky.

This site points out that Lexan is easily scratched and yellows from UV exposure.