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always happy to help ..

i believe many of the early window designs using PMM / plexiglas did not use screw holes for this reason, but used a clamping system instead (clamping the PMM sheet between the window frame and a metal band)

you might also want to be careful with some cleaning solutions and solvents - they can induce tension cracks in the plastic material (using alcohols on PC is a special no-no in this regards)

 

i think so ... building a vacu-form rigg is not so complicated .. and there are also many professional companies doing large scale vacu-forming .. it might have been possible to use their equipment at low cost, if you went there with a well prepared positive mold

btw - thanks for the information about PET .. i did not know about it being used for cockpit windows ..

Markus