F-15C - Making the Right Glareshield

You'd think that heat forming acrylic would be a great big pain in the butt, 
wouldn't you?  That isn't necessarily so.

Rob and I had been scratching our heads on how to build a good replica
of a glareshield half we'd never seen.  I had gotten my hands on the left
hand half a couple of months ago, so we knew how long it had to be.

Eventually, Rob started working on a 1/8" MDF replica of it.  This turned 
out ok, but wasn't exactly what was needed.

This last Saturday, we started working on it again after a long hiatus.

Rob built another template to use and we set it into position over the 
right instrument panel half.  We wanted to use a 1/8" sheet of Lexan to 
create the new glareshield half.  After trying a couple of different methods
including a pair of 1000 Watt lamps, we got stumped as to what we could use
to form the plastic.

After wandering around the shop a bit, I said to Rob: "Look, the only thing
I have left that would generate a lot of heat is the propane space heater".

I'll be a son of a bitch.  Necessity IS the mother of invention!  Hehe.





Yes, he's doing exactly what you think he is.  A propate space heater IS
a hand-held tool when the need arises!  (Don't try this at home kids, we're
Professionals of Mechanical Improvisation)

It looks pretty crazy alright.  As Rob heated the plastic I (wearing gloves)
formed the plastic around the makeshift mold by hand.  Eventually I used a
short plywood "stick" to keep from getting burned any more than I already was.
(Ok, not exactly burned, but "well heated" to say the least.)

Below is the result:




The result was pretty impressive considering the methods we used to get to this
point.

Here is what it looks like painted up and and re-installed:






There is still some finish work to be done, such as adding the rubber coaming
to the leading edge of the glareshield half and making hold-down brackets so
it will grip the instrument panel.  All in all, I'm impressed with the result!