Hey Just thought I'd share this as I had some trouble finding topics about making screens.
just so happened (care of new road repair and loose gravel on a blind corner) I was in need of a new screen and didn't have a lot of time to get one
![](http://i.imgur.com/qJoYGsMh.jpg)
![](http://i.imgur.com/npXI0vYh.jpg)
So here's what I did
Local hardware and get a piece of 3mm Acrylic (tip: get enough to make more than one and perspex is a better option but this was handy) and draw a rough outline (I used a piece of the broken screen to get it roughly in shape)
![](http://i.imgur.com/eqiBqUOh.jpg)
Cutout with care
and a fine jigsaw blade
![](http://i.imgur.com/YFXohRuh.jpg)
![](http://i.imgur.com/5bXjSNjh.jpg)
For the next bit get a tray, some sand and form a rough mould (tip: the spray bottle is to keep the sand wet).
![](http://i.imgur.com/qj2SHhlh.jpg)
Not a lot left but it's a start to make the right shape
![](http://i.imgur.com/xyDKLabh.jpg)
Lay Aluminium foil over the sand (no the acrylic doesn't stick to it) put it in a big oven (ok the Mrs was a bit concerned I was going to use the house oven) BBQ cranked up works well enough. Lay the cutout over the mould
![](http://i.imgur.com/9tTAGRyh.jpg)
Around 275C worked pretty well give it ten minutes or so or when it's visibly pliable and drooping, it was pliable enough to press it down with my welding gloves on. Allow to cool somewhat and (OK! modelling skills need work)
![](http://i.imgur.com/JLEVTJ9h.jpg)
I was planing just to reheat this one after I had trimmed it up better but managed to crack it and then it warped when I applied the heat gun
![](http://i.imgur.com/PAyKUrMh.jpg)
So I used this one as a better template and shaped the sand to a better curve
![](http://i.imgur.com/Op8cY6ih.jpg)
VOILA!!
![](http://i.imgur.com/tom6Nibh.jpg)
Half a days work and getting there
![](http://i.imgur.com/F6UgWYHh.jpg)
just so happened (care of new road repair and loose gravel on a blind corner) I was in need of a new screen and didn't have a lot of time to get one
![](http://i.imgur.com/qJoYGsMh.jpg)
![](http://i.imgur.com/npXI0vYh.jpg)
So here's what I did
Local hardware and get a piece of 3mm Acrylic (tip: get enough to make more than one and perspex is a better option but this was handy) and draw a rough outline (I used a piece of the broken screen to get it roughly in shape)
![](http://i.imgur.com/eqiBqUOh.jpg)
Cutout with care
![Smile](https://katriders.com/core/images/smilies/icon_smile.gif)
![](http://i.imgur.com/YFXohRuh.jpg)
![](http://i.imgur.com/5bXjSNjh.jpg)
For the next bit get a tray, some sand and form a rough mould (tip: the spray bottle is to keep the sand wet).
![](http://i.imgur.com/qj2SHhlh.jpg)
Not a lot left but it's a start to make the right shape
![](http://i.imgur.com/xyDKLabh.jpg)
Lay Aluminium foil over the sand (no the acrylic doesn't stick to it) put it in a big oven (ok the Mrs was a bit concerned I was going to use the house oven) BBQ cranked up works well enough. Lay the cutout over the mould
![](http://i.imgur.com/9tTAGRyh.jpg)
Around 275C worked pretty well give it ten minutes or so or when it's visibly pliable and drooping, it was pliable enough to press it down with my welding gloves on. Allow to cool somewhat and (OK! modelling skills need work)
![](http://i.imgur.com/JLEVTJ9h.jpg)
I was planing just to reheat this one after I had trimmed it up better but managed to crack it and then it warped when I applied the heat gun
![](http://i.imgur.com/PAyKUrMh.jpg)
So I used this one as a better template and shaped the sand to a better curve
![](http://i.imgur.com/Op8cY6ih.jpg)
VOILA!!
![](http://i.imgur.com/tom6Nibh.jpg)
Half a days work and getting there
![](http://i.imgur.com/F6UgWYHh.jpg)
![](http://i.imgur.com/UHpiNCgh.jpg)
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