1) Since it has been quite a while since I have updated, I looked for things I had not posted. Here are some of the ones I forgot about.
I have a cardboard pattern cut out and sort of fit to the A/C. but it isnt really a tight fit as I wanted to finesse the lexan during fittment.So there is a bit of lexan to trim, as shown here
2) I covered the bench with cloth to try to make sure no alumunium flakes from prior work scratched the plastic. I have to disown the ownership of the red sheets...Good Will supplied them!!
3) I began cutting the sheet, utilizing a very large jigsaw table! I have been given an nonfunctional varriable speed, decrepit, Bosch jigsaw, and was able to rework it to fit under the bench, set to its slowest speed. I installed a plastic cutting blade and just slid the large sheet around to cut the excess/first pass trim amount off. This enabled me to cut solo, and gave me a plastic sheet that could be worked for fiting to the A/C. This necesitates constructing a foot switch to activate the saw.