Clear plastic hatch cover

[Thistle]

I need to make a clear (or translucent) plastic hatch cover of a non-standard size. What material should I use? Plastic sheet? (what kind?) Clear epoxy and glass mat? The shape is basically simple. How should I mould the material to the desired shape? I have the old one: can I use it as a former? (I don't mind the new one being slightly oversize.)

All help gratefully received.

Thanks.

 

[greenalien]

You could try looking for a local vacuum moulder, and get one made in perspex, using your original as a template. What material is the original made of?

 

[Thistle]

You could try looking for a local vacuum moulder, and get one made in perspex, using your original as a template. What material is the original made of?

It's a plastic of some sort - sorry I can't give a better answer. It seems to have gone brittle with age and / or UV to the extent that gaffer tape can no longer keep up with the cracks.

Thanks for the vacuum moulder suggestion: I'll follow that up.

 

[Tranona]

Most appropriate material is a polycarbonate such as Lexan. You can get it cut to size at any sign maker. Available in a choice of sizes (probably 6-8mm would be right for a hatch) and tints. Stronger and more UV resistant than acrylic.

 

[nimbusgb]

What sort of size? More than a couple of inches across it will have to be 10mm thick to prevent someone stepping on it from going through. More than about 400mm on an edge and step up to 12mm or more!