Tony -
Do you take photo requests? I'd like to see what shape you settled on for the opening through the bulkhead... I really liked the rounded-corners one that you had prototyped in cardboard back many pages ago.
Also, I'm thinking that I am going to sell my window frames, and go with Lexan bolted on from the outside. Probably too late for you to be interested in them, but I thought I'd mention it in case your molding hasn't progressed too far, or if you run into troubles with it (which I hope you don't! I considered doing something similar a while back...).
She's looking reeeaaalll nice.