Got a Kamtec Baja ABS shell that's been lying around for ages, I've managed to roughly cut the outline using the old score-with-knife-and-fold technique, needs a bit of tidying up but it's going to look right when it's done.
I came to do the windscreen but because I couldn't twist the plastic, I had a horrible time trying to get it out. Score after score after score in a 'scrap' area eventually broke through (using a brand new craft blade), but I still had a lot of trouble getting the windscreen out. I didn't want to repeat-score over the actual window edge because I can't be sure I'll get the curved line right the second time and would end up with a messy window.
The smaller windows will be even tougher. I'm thinking I'll have to put a cutting bit into a vice-mounted dremel and offer the shell up to it to get a rough cut, then tidy up with abrasive paper.
Any other suggestions considered