Just a question, has anyone tried forming the lexan over a stock glass curved window? I assume using body shop heat lamps and clamps would be the way to go. Do you cut it with a jig saw and a fine blade? Tap plastics probably could give us the answers, or maybee if you made a paper template, it might be worthwhile to pay them to cut it. They did my tail light lenses, and the cuts were really smooth, but I never thought to ask them what they used.
They also sell drill bits for plastic, and I got a how-to sheet from them on the best proceedures for drilling. Bob