The plastic side ports in my 1989 mk1 are leaking. I would like to replace them, and am planning to remove the old ones and use them as a pattern to cut new ones with a router. I would like your advice.

What kind of plastic should I use? Polycarbonate or Acrylic.
How thick.
What color---I purchased some 1/4" clear acrylic, but am having second thoughts. Smoke or green color might look better?

I plan to use the Dow Corning sealant that Catalina Direct sells. Is this the best thing to use?

Any advise anyone has on the above items, or suggestions on how to remove the old ports and sealant residue or any other experience would be appreciated.

Gary Teeter
1989 C36 #966
AnnieG
Everett, WA