Time for some more updates!
Firstly, their is the one-off custom plexi rear quarter windows. The goal here was a much flusher fit to the body, extreme light weight, and an inconspicuous look. The material is 3mm thick for lightweight, and uses a lightweight plywood frame to hold it in place.
Here is the ply frame ( painted black ) and the plexi cut from templates.
Here is the frame in place - it mounts through about half a dozen screws drilled through the window frame. The resulting gap between body and ply frame is filled with a low tack silicon sealant to ensure the window is weatherproof.
Note in the previous pic the edge of the plexi window on the inside was painted black to hide the glued area. Now the window is glued in place to the frame - again with a glazing silicon.
And the outer plexi mask removed.
The inside of the ply frame provided a glue point for the suede headliner. Suede also wraps the B pillar and lower section of the window frame, to neatly finish the interior trim to the window. You can also see below the suede headliner, which is a single piece of suede front to back. Not difficult in a sunroof car as the headliner trims up to the sunroof opening. The key is to get it tight and even, as suede has very little stretch.
Lastly the inside masking is removed ( when the glue has dried ) and the side windows are complete.
You may have also noted the 3mm plexi rear screen too. This is installed using an OEM window seal, although some cuts and re-seal were required in the corners due to the material being thinner than stock. Making the plexi a touch larger than the OEM glass naturally pushed it into a very stock looking curve when installed. More pics later..
Then it was onto the interior trim...