Cutting it with a bandsaw, file and sand edges. I was offered Lexan, but decided on the plexi as it's what was there originally (Perspex). I've an "infinite" supply, so if it gets "funny" I'll just re-make 'em later out of Lexan.
The insert is a PITA with an old gasket, Rick. I made a tool from a coat-hanger (to look like the tool in the Bentley manual) and gripped it with ViseGrips to do this job. Stuffed it in the channel with me thumb. Couldn't locate the tool I *know* I have! /ubbthreads/images/graemlins/wink.gif
ETA is two or three weeks. We'll see. Herself needs to get on the stick and stitch up the upholstery for interior panels and seats now.