When I worked at a plastics shop when I was 19 or so , I saw the owners son make one on his break times . He at home took and made a plaster mold of his windshield , by laying windshield upside down and putting plaster on it . He then used the oven we had to get the plastic sheets pliable for vacuum forming . You put the sheet in a wooden frame and clamp it down before baking , and remove with mitts . Once the plastic sheet was drooping , he removed from heat , pressed onto mold he had sitting on a stool , let cool , trimmed it , scraped edges with a knife to deburr , used a torch on the edges to make it look like glass . And installed it when he went home /forums/images/graemlins/k5.gif
