-=> Quoting A Welch's Question <=-
 AW> Has anyone had to form their own canopy by melting tranparent plastic
 AW> sheets over a mold?  I know there was an article on doing this in a 
odel
 AW> magazine years ago.  I'd like some advice on how it's done and how the
 AW> mold is made.
Yep. First you need a plug in the shape of your canopy. Make it from
hard wood if you can or very hard balsa.
Second. Mount it to a base of some kind, like a board or plywood plate.
Add a spacer under the plug. It can be the same size as the base of the
canopy or part being molded. It doesn't have to be inset like I've
drawn it.  The purpose of this is to give you some flashing at the
bottom of the canopy part to cut off when finishing the part.
                /***********+++++..   <- - - - - - - - - Canopy
              /____________________\
            ______|___________|______________ <- - - - - Ply.Base
                                                         Note Space!
Third. Finish it with resin and then paint it with epoxy. It has to be
smooth as glass with no defects.
Fourth. Get some sheet plastic in the thickness you want.
Fifth. Build a frame to hold the plastic sheet. Thin plywood works OK.
     \-/    \-/   \-/   \-/
      |      |     |     |   <- - - - - - - Screws or small nails
  ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ    <- - - - - Frame Material 1/8 ply or
  ÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ    <- -\            Equivalent
  ÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍÍ        |
                                     |
                                     \- - - Plastic Sheet of desired
                                                  Thickness
 ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿
 ³ *        *       *       *      *   *  ³
 ³   ÚÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄ¿    ³
 ³ * ³                               ³ *<-³- - - - - - -Screws or small
 ³   ³                               ³    ³             nails
 ³ * ³                               ³ *  ³
 ³   ³               <- - - - - - - -³- - ³ - - - - - - Plastic sheet
 ³ * ³                               ³ *  ³
 ³   ³                               ³    ³<- - - - - - Frame/Plastic/Frame
 ³   ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ    ³             Sandwich
 ³ *        *       *       *      *   *  ³
 ÀÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÄÙ
Sixth. Make a "sandwich" of two frames and the plastic sheet as shown
above. Use screws or small "finishing" nails to hold it all together.
             _____________ FORMING THE PART _____________
        ***** WARNING ***** USE PROTECTIVE GLOVES! YOU CAN GET BURNED!
        Place your oven rack on the top or next to top position.
        Turn it on at about 350*F and let it get hot.
        Place the framed plastic on the rack and watch it.
        When the plastic starts to "sag", remove the frame and force it
        evenly down over your plug.
        When it cools, you will have a very nicely formed canopy. It
        also works for other small parts too.
Buy extra plastic. You will make mistakes and will need practice to get it
right.  I also saw an article not too long ago where plastic soft drink
bottles were used as a source of plastic for small parts and canopies.
                                                |     |
                                                |  _  |
 ________ Eddie _________         ______________|_( )_|______________
  LawCo Marine Surveyors             o   +|+   [ ( o ) ]   +|+   o
      Wilmington, NC                          *[_]---[_]*
--- FLAME v1.1
(1:3628/5)
---------------
** A related thread FOLLOWS this message.

FIDO MESSAGE AREA==> TOPIC: 131 RADIO CONTROL Ref: D5PL2569 Date: 05/20/96
From: A WELCH                                               Time: 05:42pm
\/To: EDDIE WARREN                                        (Read 3 times)
Subj: R: FORMING CANOPIES

EW>Yep. First you need a plug in the shape of your canopy. Make it from
EW>hard wood if you can or very hard balsa.
EW>Second. Mount it to a base of some kind, like a board or plywood plate.
EW>Add a spacer under the plug. It can be the same size as the base of the
EW>canopy or part being molded. It doesn't have to be inset like I've
EW>drawn it.  The purpose of this is to give you some flashing at the
EW>bottom of the canopy part to cut off when finishing the part.
EW>                /***********+++++..   <- - - - - - - - - Canopy
EW>              /____________________\
 
Say thanks for the detailed information on canopys *and* very good
graphics!  I have copied the text for referenece and should have no
trouble making the plastic dial cover I'm needing.
---------------
>>>>>>>>>>>>>>>>>>>>>> LAST Message In Thread <<<<<<<<<<<<<<<<<<<<<<

FIDO MESSAGE AREA==> TOPIC: 131 RADIO CONTROL Ref: D5P00007 Date: 05/13/96
From: EDDIE WARREN                                          Time: 09:48pm
\/To: RODNEY REA                                          (Read 3 times)
Subj: GLIDERS

-=> Quoting Rodney Rea to Glider Guiders <=-
 RR> Hello, all. I was just wondering if there are any glider flyers
 RR> around this echo. Let's hear from you and what you're flying or
 RR> building. 
 RR> Any good contests around?
Before I kinda dropped out of the flying hobby about ten years ago, I
had gotten into sailplanes. I still have three here in various stages of
(dis) assembly. One is a Nomad which was kitted by Balsa USA way back
then. I have another 10 footer but I don't know what it was called. I
didn't build it but inherited it from a friend. I also have a drifter II
kit that was barely started.  Haven't done much in the airplane line
having gotten into RC Boats, but I've been thinking of converting one or
more of them to electric power. Have you given that any thought?
________ Eddie ________
--- FLAME v1.1
(1:3628/5)
---------------