Wonwings diary-dealing with Transparent Mouldings in the home workshop.
Have you ever been faced with making a large transparent canopy ? well if you dont know how to go about it stick around a minute for a method that costs you no more than your favourite soft drink,the material that large bottles of soft drinks come in is ideal for or task but first we need to make a plug,dont worry at mention of this, it is a simple task,just grab a block of balsa the size of your canopy and mark out first the side view,cut this out with a band saw or if you dont have such a luxury a keyhole saw will suffice,next mark the plan ( top ) view and cut away the surplus wood,finally use a surform or similar to shape the block,smooth the edges with glasspaper,if you wish you can face the bottom portion with a piece of ply,this does strengthen the plug and give that extra bit to play with whilst trimming the canopy etc.
Next take the large drinks bottle and cut off the top portion at the neck,place the carved block of wood into the bottle and ram in some rag of similar to blank off the open end,now take your heat gun ( you can use any hair drier or heat gun with care ) and play the heat evenly onto the plastic,what will happen now is the plastic bottle will shrink itself up tightly against the wood former,just be patient and do not get too close otherwise you will burn the plastic,practise will soon pay off as you get to know just how close you can get without spoiling things,leave to cool off and with your Stanley knife run a line at the base of the canopy and trim up with a pair of scissors,result one new canopy for your pride and joy.
There is another way to make smaller canopies or plastic mouldings,the results will surprise you and like the plug in bottle technique a little practise and a few failures will bring forth expertise in the task,and better still results.
Modern cosmetic gift wrapping material is ideal for making up transparent mouldings,never throw such material away as it is just ideal for modelling,in order to avoid heat spots wash the material in warm soapy water,clean and dry off with a chamois and leave to air dry.Get the best by positioning across the female mould,dont forget to allow some extra material for the depth of the draw,spacing the staples will also give more plastic to pull through without lappin onto itself in the process,a few experimental plunges will give you an idea of how deep the plug will go into the hot plastic without curling back.
This is the time established way of making small cockpit canopies,simply carve a plug from balsa wood,make a female mould from a piece of ply slightly oversized to allow for the deep draw of the plastic sheet,pin or staple the sheet to the female and heat over a gas or electric ring until the material becomes floppy,then plunge the plug into the mould,wait for a few seconds to cool and withdraw the plug,you will probably need a bit of practise and a bit of wasted material in the process but practise makes perfect and that is the secret.
To trim up firstly use a chinagraph pencil to mark the base line,then with a pair of sharp curved nail scissors carefully cut outside the line,a permagrit abrasive block will easily clean up the edges,but beware of scratching the material.
Have you ever been faced with making a large transparent canopy ? well if you dont know how to go about it stick around a minute for a method that costs you no more than your favourite soft drink,the material that large bottles of soft drinks come in is ideal for or task but first we need to make a plug,dont worry at mention of this, it is a simple task,just grab a block of balsa the size of your canopy and mark out first the side view,cut this out with a band saw or if you dont have such a luxury a keyhole saw will suffice,next mark the plan ( top ) view and cut away the surplus wood,finally use a surform or similar to shape the block,smooth the edges with glasspaper,if you wish you can face the bottom portion with a piece of ply,this does strengthen the plug and give that extra bit to play with whilst trimming the canopy etc.
Next take the large drinks bottle and cut off the top portion at the neck,place the carved block of wood into the bottle and ram in some rag of similar to blank off the open end,now take your heat gun ( you can use any hair drier or heat gun with care ) and play the heat evenly onto the plastic,what will happen now is the plastic bottle will shrink itself up tightly against the wood former,just be patient and do not get too close otherwise you will burn the plastic,practise will soon pay off as you get to know just how close you can get without spoiling things,leave to cool off and with your Stanley knife run a line at the base of the canopy and trim up with a pair of scissors,result one new canopy for your pride and joy.
There is another way to make smaller canopies or plastic mouldings,the results will surprise you and like the plug in bottle technique a little practise and a few failures will bring forth expertise in the task,and better still results.
Modern cosmetic gift wrapping material is ideal for making up transparent mouldings,never throw such material away as it is just ideal for modelling,in order to avoid heat spots wash the material in warm soapy water,clean and dry off with a chamois and leave to air dry.Get the best by positioning across the female mould,dont forget to allow some extra material for the depth of the draw,spacing the staples will also give more plastic to pull through without lappin onto itself in the process,a few experimental plunges will give you an idea of how deep the plug will go into the hot plastic without curling back.
This is the time established way of making small cockpit canopies,simply carve a plug from balsa wood,make a female mould from a piece of ply slightly oversized to allow for the deep draw of the plastic sheet,pin or staple the sheet to the female and heat over a gas or electric ring until the material becomes floppy,then plunge the plug into the mould,wait for a few seconds to cool and withdraw the plug,you will probably need a bit of practise and a bit of wasted material in the process but practise makes perfect and that is the secret.
To trim up firstly use a chinagraph pencil to mark the base line,then with a pair of sharp curved nail scissors carefully cut outside the line,a permagrit abrasive block will easily clean up the edges,but beware of scratching the material.