I removed the windshield and beveled the edges with a 60 grit 2 inch sanding wheel on a pneumatic grinder, as called for by L.P. Aero, the vendor for the windshield. They also specify the holes should be at least 1.33 times larger than the diameter of the screws to be used. In this case, I'm going to use 8-32 screws, so I went with 1/4 inch holes, which were over-drilled with a plexiglas drill bit. I then overdrilled the windshield post holes to fit a 8-32 shank, and used a nutplate guide to drill the nutplate holes for a mini-corner nutplate. The holes were then deburred, the nutplate holes were countersunk and painted with Zinc Chromate primer with a small modeller's paint brush, and the nutplates were riveted.
Windshield beveled and mounting holes drilled to 1/4 inch.
