Step by Step Installation
Warning: You should be sure and read all safety precautions provided with power tools before using them. This usually includes wearing safety glasses.

First thing I did was remove the case door from my Addtronics 6896A and place it on a flat table. I then placed the acrylic window in the general location of where I wanted it to be and carefully measured out the distances between the edge of the case and the window making sure it was at least ½ inch away from the edge. After that, I placed double-sided tape between the window and the case in order to keep the window in place so that I could draw around it. Taking the included spacer (washer) in the window kit, I carefully drew around the window with a pencil outlining where I wanted to cut. After this it was time to cut.

For cutting the case I used a combination of the flex-shaft, quick change chuck, and a combination of the 1-1/4" Fiberglass-Reinforced Cut-Off Wheels, and 15/16" Cut-Off Wheels.

(Flex-Shaft)

(Keyless Quick Change Chuck)

(1-1/4" Reinforced Cut-Off Wheel)

(15/16" Cut-Off Wheel)

Now it was time to commence cutting. I carefully followed the pencil line I had created and cut out the window. Cutting around the corners was the most difficult. I couldn't directly cut out the corners without breaking the cut of wheel so I took out small chunks until I achieved the desired result.

After cutting out the wheel I used the aluminum oxide grinding stone to smooth out the edges and remove any loose pieces of metal remaining. I also used the dressing stone for getting around the corners. (Note: Be very careful at this point because the metal is very sharp and can easily cut you.)

(Closeup of Rough Edges)

(Grinding Stone Used)

Now it was time to install the molding for the window. I placed the molding around the cutout and trimmed of what access I had left. Next it was time to install the window. This was the most difficult part of the whole project. It took me quite some time to appropriately place the window into the molding while keeping it connected to the case and window. After several tries and almost reaching the point of throwing it out the window, I finally accomplished it. The next step was to install the locking strip. I found this step to not work quite as it was suppose to. Supposedly the strip is suppose to stay in the groove once installed but for some reason it just didn't cooperate to well for me. I would get the strip installed but then after leaving for an hour and returning I would find that the strip had popped out of the groove. After trying to install it several times and just having it pop out again I finally resorted to using the greatest invention ever to install it, superglue. Well needless to say, the strip didn't come out after that.

(Window Installed)

(Inside of Window Showing Locking Strip)

(Closeup of Outside of Case)

In order for the door to properly fit back into my Addtronics 6896A case, I had to make a few additional modifications to the window. There are two metal divisions in the addtronics case which get in the way of the window molding. To eliminate this I simply cut out the molding around those areas. To do this I used the flex-shaft and 15/16" cut-off wheel.

(Metal Divisions Which Stopped Door From Closing)

(Molding Cutout to Fit Around Metal Divisions)

Finally, I placed the door back into the case.