The Forming Secret

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 The Fabricator basically uses a big pizza oven to heat up an oversized sheet of Plexiglas. When it arrives at the correct forming temprature it is removed from the oven and draped over the lower part of the mold.  The upper plywood frame is then clamped over the Plexiglas sheet and air is immediately pumped in from the center of the lower mold.  There is a “Secret” as to how the air is introduced to the lower mold. If you just attach an air hose nozzle the result of the form will look very localized around the air nozzle location. The preferred shape is a balanced uniform inflation of the bubble around the entire frame shape.  The way this is done is amazingly simple and crude.  A piece of cardboard approximately 12 inches square is stapled on the corners over the air inlet and that’s it. That is enough air diffusion to uniformly lift the heated sheet of acrylic to its lofty formed shape.

The Photos above show the finished parts trimmed and reclamped in the mold. For Insurance, I had the Fabricator make two sets just in case I broke one later and that’s exactly what happened a few years later when I ground looped the airplane and shattered the left door with a safety cable flinging off the landing gear!

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