For the windshield I would make a pattern out of heavy paper or manila file folder material and cut it to shape. Hopefully the pattern is on your plans already. Cut out the plastic and think about how you're going to hold it in place while you heat and shape it. It can be done with a heat gun and cotton gloves. Without a plan for holding it down, you will need a few extra hands so think it through. If you overheat the plastic, it will "craze" and not be clear anymore. It can be done though. Order .060" thick butyrate plastic sheets in 11" x 17" size and get more than you need.

Pay attention to where the heat gun is pointed while you form and stretch the plastic too. Once you get the hang of it it's not "too" bad.


carl