scratch build windows

[mchengsp33]

hi, i am just wondering if anyone scratch built windows for the model before (for example, the windshield)? what kind of material should i use for such task? thanks

[mike@af]

You could, but its a pain. Windsheilds are complex curves, its very hard to get the styrene to stretch in multiple directions while looking correct and not screwing up the clarity of the styrene.

The best thing to do would be to have it vacuum formed.

[mchengsp33]

hi, what's vacuum formed?

[hirofkd]

For me, a simple heat-and-smash method works for most of the windshield, since the shape isn't so complex like say, a jet fighter canopy.

Cut a block of balsawood to make the master, and smooth the surface with 800-1000 grit sand paper. Fix it to the desk firmly.
Then, clamp a sheet of thin plastic (one of those used to pack toys and many other things from household goods to tools) and heat it with a candle fire or the kitchen stove.
Smash the heated plastic on the master and wait for a few seconds until it cools down. Remove it from the moster, and you have a windshield.

If the surface is too complex and the plastic doesn't conform to the surface of the master very well, you will need to vacuum form.

Vacuum forming is basically the same as avove in terms of using heat to soften plastic and lay it over a master. Instead of pulling the plastic down, you'll use vacuum cleaner's suction power to let it stick to the surface without any gap.

A vacuum forming machine can be made from a picture frame, stirdy box of wood or plastic and vacuum cleaner.
Try google image search by "vacuum forming machine" to get the idea of how it should look like.

[MPWR]

This is the stuff to use, and where to get it. It's not styrene- clear styrene doen't behave particularly well for this use (although the opaque white stuff can be shaped this way).

http://www.squadron.com/old/thermaform/thermaform.htm

This is really the only reasonable way to scratchbuild a windshield (don't even THINK of trying to cast one in clear resin!!), but it is a bit of an advanced technique. The trick is in getting the master right.

[p9o1r1sche]

Thermaform from Squadron is the way to go. Easy to use.