Plastic thickness for a windshield ?

Hi Matt, Not sure if this will help you.. but if I needed to make a windscreen, I'd look around my shop for something that's still packaged in that clear plastic packaging that you usually need to cut with scissors to open. Usually the "back-side" of the packaging is flat. Cut templates from cardstock first, to get the proper shape and fit.. then trace those pieces onto the clear-flat sheet and cut them out. The Tiger Moth's windscreens look to be a flat "3-piece" design that you can form by creasing the sheet using a thin rigid straight-edge.. like a steel ruler. Try a scrap piece beforehand to get the technique down.

This piece pictured is .5mil (.020") but you may want to go thinner than that.



You can form a radius if needed by laying your pieces over a curved heat-resistant item (a tin-can, glass bottle etc.) and gradually apply heat until the plastic droops around the form. You can do this with a heat-gun or in a conventional oven. The amount of heat depends on the type of plastic and the thickness.