Just this week, I took delivery of my first bash at laser cut windows. They turned out really well, and at 30 Canadian dollars for enough to re-window the whole CEP, were not too expensive. I used a local supplier here in Toronto called sawdust and noise, friendly and prompt service (usual disclaimer applies - no affiliation!)

One problem however was that as a newbie I forgot to take account of the kerf (the width of the laser beam when cutting the material) which has made them ever so slightly too small. They're still useable though as the dimension difference will be covered by the window etch which overlaps the pane itself.

I have the artwork used to cut the windows, this time adjusted for the kerf (line offset by +0.25mm from desired size) - it was drawn up in Adobe Illustrator. Just PM me if you want the file. The material for the windows was 1/8" clear acrylic.

Moving onto the body sides, I have been tackling the driving cars. I decided to take a different approach to how John Upton performed his conversion, and cut and modify the existing sides to represent the refurb.

The main difference is that an additional window aperture needs to be cut into the bodyside in the location of the old guard's compartment, and the existing guard's door covered up and raised detail filed off.

First I marked some lines very finely with a scalpel to show the position of the new window. This overlaps the position of the window in the guard's door by about 1.5mm. Then I used a drill bit to cut out the window shape, and filed it to the correct size for the new pane. Note that the window aperture must have rounded corners, so be careful not to file it square.

Next I took one of the small laser cut windows intended for the door windows and filed it down on one edge until it was flush with the edge of the new window side. I superglued it slightly recessed into the hole left by the guard's window.

Next up - cover with model filler, applying with a piece of thin plasticard to gain a smoothish finish. Apply filler to level off the guard's window, and apply it into the moulded edges of the guard's door.

When dry, file flat. I used some micro polishing cloths to get a totally smooth finish and remove any trace of a join at the guard's window edge. At least I hope so - we'll see when the primer goes on!

End result - next step is to get the window etches ordered!