This really sucks that you have to keep going through all these problems. I would say that at this point I would replace the plywood and then fiberglass it.
This thread has kept me awake in the work course I have been at the last few days (so boring....) All the best with the rest of the job. Hope it is clear sailing from now on. Cannot wait to see it finished.
While doing that last pass on the windows with my multitool scraping off the silicone the tool caught the edge and bounced across the face of the window. Making small chips into the acrylic with the end of my scraper blade. Area is about 2"x3" in the upper right side of the window.
Not too happy with my self on this one. Going to try sanding and repairing it before I freak out. Any pointers on fixing something like this? I have never buffed out acrylic before on scratches but I assume it's the same.
Here are the pictures along with the work up to today.
They make a kit for buffing it out. Essentially you start with a coarse grit special sand paper and progressively use finer and finer grit until it's sparkling, shiny, and smooth. At least that's how we did it when I used to buff out portholes for decompression chambers many years ago.
Sorry to hear about the problems with the build. I feel your pain.