lakshmi369
Seaman Apprentice
- Joined
- Nov 28, 2012
- Messages
- 42
I recently ran into a solution for a boat refurbishing project that had me stumped. I had a horribly worn instrument panel for my 1963 Hydroswift. I was able to find all the parts I needed and make a passable nice instrument panel containing a compass and a speedometer. I was stopped cold on finding the clear plastic domed lenses though. I had two original lenses but they were so clouded over they were unusable. After searching all the normal places I found a small plastics manufacturer locally that passed this method on to me:
1. Use the original lens to make a form. I sprayed the lens with cooking spray of all things so it didn't stick. I used a metal container several inches larger than the lens and poured a mix made from plaster of Paris. I pressed the lens into the wet plaster and let it sit until the form had set up enough to hold the shape. I carefully remover the original lens and set it aside for further use on the project.
2. While the plaster was curing for the next several days I cut squares of plexiglass out about an inch larger than the diameter of the original lens.
3. Using my home oven I preheated it to 325 and placed the plaster form on a cooking sheet.
4. Once heated fully I placed a single square of plexiglass on the top of the plaster form and watched it through the oven window. Took between 3-5 minutes in my oven. Once the edges of the plastic curled a little I dipped the original lens into some cool water and carefully dried the original lens and immediately pressed it into the warm plexiglass square pushing it into the plaster form to make the domed shape.
5. I removed the form and all from the oven, and using oven mitts popped my new lens into cool water to hold the shape.
6. I made several to have a couple spares on hand. After they were cool and well hardened I traced out the circular size of the lens using that original lens again and using a rotary cutting tool (Dremel works great) I cut out the circular form and I had dome lenses!!!
Here is my disclaimer- Try at your own risk! I am most certain this is not the approved way of molding plastic but I have found it to be successful for me.
Good luck and be safe!
1. Use the original lens to make a form. I sprayed the lens with cooking spray of all things so it didn't stick. I used a metal container several inches larger than the lens and poured a mix made from plaster of Paris. I pressed the lens into the wet plaster and let it sit until the form had set up enough to hold the shape. I carefully remover the original lens and set it aside for further use on the project.
2. While the plaster was curing for the next several days I cut squares of plexiglass out about an inch larger than the diameter of the original lens.
3. Using my home oven I preheated it to 325 and placed the plaster form on a cooking sheet.
4. Once heated fully I placed a single square of plexiglass on the top of the plaster form and watched it through the oven window. Took between 3-5 minutes in my oven. Once the edges of the plastic curled a little I dipped the original lens into some cool water and carefully dried the original lens and immediately pressed it into the warm plexiglass square pushing it into the plaster form to make the domed shape.
5. I removed the form and all from the oven, and using oven mitts popped my new lens into cool water to hold the shape.
6. I made several to have a couple spares on hand. After they were cool and well hardened I traced out the circular size of the lens using that original lens again and using a rotary cutting tool (Dremel works great) I cut out the circular form and I had dome lenses!!!
Here is my disclaimer- Try at your own risk! I am most certain this is not the approved way of molding plastic but I have found it to be successful for me.
Good luck and be safe!
