Time to get back to work on the car...
Had started some time back with window layouts of the sides and observation deck end of the car body. Using the CAD program, was easy to set center lines both horizontally and vertically. Remember...the "key" point was that center mark for the half moon window.
Window centers were drawn on the car side....lightly, in case I had to change something. Made a template that would be used later on to cut out the windows, but for now used the template to draw an outline of the windows on the sides of the car. Now the car was starting to look like the drawing. Had decided by this time, would simply put a round window on the sides of the observation deck and smaller round windows at the far end of the car where the lavatory might have been located.
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Next, used an awl to "punch" a starting point for a pilot drill. Would eventually open that hole with a 1/4" drill bit. This was NOT the time to deal with a drill bit or worse...a hole saw drifting out of position!
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Then, the window opening making begins. Pulled out the hole saw...which had the same outside diameter as the top of the round top window frames and started to make holes in the nice car body. No, I wasn't going to stop there. Didn't want to have a nautical looking car with a bunch of port holes down the sides! (no comments from the Navy boys reading this!)
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Next, the window cutting template was clamped to the side of the car. An aluminum angle at the top of the template provides alignment top to bottom.
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The multi-function vibrating tool used for cars #5 and #6 came out with a saw cutting blade. Let the saw blade follow the inside opening of the template. Would tilt the tool and let the saw cut in one direction. Tilt back and return the saw blade to the starting point. Best to wear hearing protection while doing this. Work with this tool too long unprotected and you'll get ringing in your ears.
Soon enough, all the window openings would be cut....5 down each side of the car and 2 on the observation deck end. If a window frame had a tight fit in the opening...could used a drum sander in a cordless drill to "ease" the half round opening. If the frame was tight in the lower part of the window opening...a file or sanding block could be used to increase the opening.
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Next time, will cut the remaining window openings, add some window trim and fit some more windows. Carl B.
