I decided to make a wind-shield out of perspex. Everyone will tell you, no don't use plexiglass; it's not safe. Well, don't read further if that's how you feel; I used plexiglass. I had a piece lying around and I wanted to see if it's as easy as they say it is. Basically, heat the perspex in an oven, lay it over a mold and that's that.
I used some floor tiles left over from a tiling job to make a base for the material to lie on in the oven. Here's a full tile and a slice that fill the oven tray completely. Notice the edge where they meet. I was concerned the perspex would be marked or would sag into this crack. Not so. I did an experiment with a small piece of material-no problem.
My heating tray with the sheet of perspex. The protective film needs to be pulled off before putting it in the oven. The side that was covered must face up in the oven. There's a residue of adhesive that will stick to the base if you place it the other way around. After cooking and molding and cooling this adhesive residue can be pulled off like a film.
I used a 1150 GS wind shield for a mold. I cut newsprint in strips about 50 mm wide and laid wetted strips to cover the inside surface. I don't think it's necessary. The perspex seems to not stick.
Preheat the tile base in the oven to 165 C. Then put in the perspex and let it soak heat for 20 minutes.
Preheat the tile base in the oven to 165 C. Then put in the perspex and let it soak heat for 20 minutes.
Here's what it looks like.
When hot the perspex will be very rubbery and will easily follow complex curves. There's a limit-remember you are not stretching or compressing the material.
Notice in the photo of the shaped material, it's flexible enough to follow the rounded outer surface and the upturn deflector part at the top.
When hot the perspex will be very rubbery and will easily follow complex curves. There's a limit-remember you are not stretching or compressing the material.
Notice in the photo of the shaped material, it's flexible enough to follow the rounded outer surface and the upturn deflector part at the top.
I made the mounting bracket out of 10mm round bar. It's tricky getting all the angles right.