The sharp corners of the windows were a tearing point of the original design, that was corrected by radiusing the corners.
Removing the least amount of material and a good radius on the cutout will impact the least, but most will do a hack job ( and think it's first class
) and remove all the material back to the fold.
I have almost 40 years of working with commercial aluminum/glass and steel doors under some of the most abusive conditions ( namely shopping centers, public buildings and schools), and learn to diagnose all types of problems with swinging and sliding doors, and find a way to remedy the problem... some so simple, that only after doing the repair that an engineer believed me... in other cases, the repair was made away from where the problem was to correct it.
As I said in the previous post, SDP completely changed the design of the door upper on the later TD Pinzes... I can't say to their reason, but the newer tops have adjustments and are a lot stronger.
Morris, there are pics of the T nuts in the yahoo group, and suppose in the SDP-Pinzgauer site also, as I had done that 10 years ago
... and to get somewhat back on topic, and not let someone get confused...
The snorkel assembly on the TD stays entirely within the cab area and does not intrude into the cargo area, as the cab has another 8" of length behind the seats and in front of the bulkhead
