In the crash and rebuild forum, I've outlined a rebuild of a Hanger 9 Taylorcraft. It had the entire front end destroyed including windscreen and side windows (six). Parts are no longer available for the plane and I wanted to expand the framework slightly any way to gain some strength so the windows were resized a bit. Today, I experimented with making the windows and found it quite easy to do. No doubt this has been covered in the past but I've not seen it so will outline how it was done.

I used a large oval discarded crock pot oven kept for warming an engine to replace bearings. Needed will be a female mold to match the size of the opening and thickness. The male mold also must match the thickness and be 1/16 smaller around.

Step 1- lay down a piece of wax paper to keep the polyethylene from sticking to the oven if it overheats a little.
Step 2- lay the male mold in the oven.
Step 3- lay a piece of 15 thousandths sheeting on the male mold cut at least 1/2 inch oversize around.
Step 4- lay the female mold over the sheeting and align equal spacing around the male mold.
Step 5- lay a scrap piece of plywood on top of the female mold
Step 6- lay a weight on top of the plywood
Step 7- turn on oven, cover and watch. Mine took less than ten minutes and the weight drove the female mold over the male mold and bottomed.
Step 8- turn off oven and let cool.
Step 9- remove, trim lip to about 1/4 inch for glazing into model after covering. Window sits flush to outside and glazes inside.

I have such a hard time with this web site requiring multiple attempts at everything that I won't upload pics here but they are available on a rebuild page for the Taylorcraft. The making of the windows is at the end of that page.

http://pages.suddenlink.net/arlyn/tcrebuild.html