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I addressed the same issue with a Lionel caboose I detailed.  I re-used the factory windows but with a modification that allowed them to be fitted flush.  I trimmed the edges down all the way down, and colored the edges with silver followed by black.  I inserted the modified windows from the outside carefully making sure they were flush to the car body.  Finally I "tacked" them in place from the back side with Future floor wax (liquid acrylic) using a small paint brush. 

I plan on finishing my Atlas SWs this way too.  window-1window-2

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Blackening the window edges is suggested in the instructions from Chooch, along with blackening the interior edges of the window opening itself, where the window insert fits in. Using a magic marker works well. The window edges are a piece of cake and with a little care and a steady hand the window openings aren't bad either. 

The difference between blackening and not blackening is amazing. Chooch inserts are about 1/8" thick and they just disappear. Great improvement!

BH 

Last edited by up148

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