Digging through an old photo album I found these.
Step 1 would be to make a paper pattern that fits as you want.
Step 2 is to transfer the flat pattern to a sheet of Plexi Glass (Acrylic), cut it out and sand the edges smooth before removing the protective covering.
Step 3 Lay the plastic on a cotton flannel sheet that is larger than the plastic part.
Step 4 is to heat the sheet in some sort of oven until it is very noodley.
Step 5 is to pull the plastic and lift it by the corners of the flannel sheet and lay it on to a form. This form is simply a piece of 3/4" plywood with a 12" radius cut on it and a sheet of .020" aluminum wrapped over it. When it cools you're done. Just have to make a flange and mount it. This flange in the picture was pounded out of .060" 6061-O condition aluminum.
Additional information on the windshield patterns and patterns for the flanges are in Acro Sport Newsletter # 62.
Step 1 would be to make a paper pattern that fits as you want.
Step 2 is to transfer the flat pattern to a sheet of Plexi Glass (Acrylic), cut it out and sand the edges smooth before removing the protective covering.
Step 3 Lay the plastic on a cotton flannel sheet that is larger than the plastic part.
Step 4 is to heat the sheet in some sort of oven until it is very noodley.
Step 5 is to pull the plastic and lift it by the corners of the flannel sheet and lay it on to a form. This form is simply a piece of 3/4" plywood with a 12" radius cut on it and a sheet of .020" aluminum wrapped over it. When it cools you're done. Just have to make a flange and mount it. This flange in the picture was pounded out of .060" 6061-O condition aluminum.
Additional information on the windshield patterns and patterns for the flanges are in Acro Sport Newsletter # 62.
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