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Comment by zbyszek Kedziora on October 10, 2018 at 2:27pm

Hi All

I am planning to make the bubble plexi door using presented below method. Can anybody advice me about any detailed information such as: recomended plexi thickness, heating temperature, other parameters, method of shaping (hand method ? stamp ?). I will be appreciate for any suggestion. Thanks!

Comment by giuseppe lomonaco on August 6, 2010 at 4:18pm

Hi Jeff , sorry but just yestreday i've broken my bubble doors on 750 !!!
I started the engine with door opened and air generate from prop have broken the left door !
Now i'm thinking to build the door in alluminium !
I'm now write to you for know if possible how you have create the shape .
Thank you for you attention.

Peppe

Comment by jeff fortune on March 18, 2009 at 10:14pm

Process:
- build door perimeter per plans or modify as desired
- cut flat plexi to fit door frame, then drill and cleco plexi to frame
- build wood box as shown in photo to fit your stove or other heat source and to fit door frame. Make sure the box is tall enough to provide evenly distributed heat rising from stove onto plexi.
- place plexi cleco'd into door frame onto box with plexi down, frame up so you can work the plexi down from the frame, into the hot chimney to create the bubble shape
- turn on stove, gradually build up heat until plexi begins to soften, then work plexi with golved hands down into wood "chimney" to slightly more than desired bubble shape, then remove head and continue working plexi to desired shape as it cools.
- that's it!
- I then removed cleco's and attache exterior trim with screws from the exterior, thru the trim, thru the plexi, into to door frame tubes that are hidden beneath the aluminum door frame. The screws each had a dab of silicone cement to hold them in place.
Good luck,
Jeff

Comment by Kevin McCune on March 18, 2009 at 8:52am

Jeff could you tell us more about you bubble door construction?

Thanks
Kevin