Hey Frank,

I've taken to making my own. I use PETG Sheet - Clear - 12x24x.060 that I got on Amazon here:

https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

I don't have a vacuum forming setup, so I use the "push" forming. I make a form of the shape I want and then make a plate with a hole that is around 1/2" larger in all directions. I clamp a piece of the PET to it, heat it with a heat gun until it sags (but not so much it bubbles) and then push the form into the hole. Here's the form and plate I just made for the tip lights on my Turbinator2.



Here's the resulting lens and one I made for the landing light in the tip tank. That one was done the same way only I used the end of the tip tank as a form before I cut it off.







Bob

I recently started developing a range of standard scale accessories.
The first items are light lenses and vents/ grills.

The lenses are 3D printed and compatible with our 5W LED lights and controller system.

https://www.ultimate-jets.net/collec...el-accessories

I will also be adding progressively a range of ordnance and pylons at scale 1/7, 1/5 and 1/4.

Great idea Bob, thanks for sharing that!

Welcome, Franko.

For really small ones, you can hack up a plastic soda bottle. I've done that a few times with some balsa and foam builds.

It wouldn't work for the larger ones, but I remember seeing someone use toothbrush handles for colored lenses before. He just ground (grinded) the handle into the rough shape of the lens, then polished it back to a shine.
I always thought that the same process might be doable using acetate screwdriver handles and they might be easier to polish since you could just sand to like 600-800 grit, then polish by dipping in acetone.
Just a thought.

Forming them is actually really easy. I knocked out the forms above for the wingtip lights in less than 30 minutes. The male form is just balsa sanded to shape CA'ed to a wooden dowel. I hardened the form with CA after rough forming it and then sanded it down with 220 grit followed by 600 grit. I cleaned the sanding dust off with alcohol and made the female form with 1/8" lite ply.

The 0.06 PET sheet is $9 for enough to make at least 20 lights and is thick enough that when "pushed" through the female mold it stays thick enough to be durable and hold its shape...

Bob

Nice tip Bob...