I like the vacuform idea. I haven't thought of that. I'm trying to avoid buying another kit just for the windshield and like you said, I'd still have to deal with those distortion issues. I'm going to give the vacuform some serious consideration. Thank you so much for that idea!
No problem... but I was thinking about this the other day... you may not have to build a whole vacuform table at all. You could probably get away with using some clay and pushing the broken windshield into it... then make sure the edges aren't covered by the clay... stick it to the end of rod and then stick it into a base. Take some cooking spray and spray it so that nothing will stick to the surface. Then take the clear plastic and hold it over a candle flame until the center starts to get droopy... and then quickly force the sheet down over the broken windshield. Hold there for a few minutes until it hardens completely. That should give a pretty good replicate. Always good to try new methods... really keeps your mind sharp!
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