Ooops! Setback: Lexan Thermoforming on Halt

by Web FishOct 20, 2012 @ 07:59pm

The original plan was to use the hill frame as a template for extrusion of polycarbonate (lexan) shells which can be further built out from the inside for structural integrity and flood control (splitting the hull in multiple water-tight compartments to minimize the impact of potential hull breach). Initial small-scale tests were very promising - getting 4:1 extrusion ratio out of the standard Lexan sheets (Home Depot). Having built the hull frame and a sliding rig to hold the Lexan sheet on a deck profile cut-out, it was time to get serious. Unfortunately, heating uniformly 8 square feet of Lexan turned out to be a bit of a challenge. Long story short: we have two options: either build ourselves a vacuum thermo-forming chamber or switch to plan B.


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