First you start with your sheets of Lexan....cut to a decent size for working with.

Then the sheet has to be heated in order to allow it to be molded.  Excuse the old dirty oven.

Because this process takes a little while, you might as well do it while you make dinner...maybe some pasta.

Now, checking on the sheet, you will notice that Lexan clouds when warmed. Plexi does not do this.

You want to continue to check it to determine the appropriate temperature to get it to be flexible.

Once it is flexible, the sheet removed and placed in my mold. Once cooled and shaped its removed from the mold.

One of the problems with Lexan is that there is an exact temperature that it reaches to allow shaping. Any warmer and it can cause imperfections. Shown below.  You can see all the small dimples.  Basically ruining this sheet.

It doesn't look like much in these pics, but it makes sense as the project progresses.   Below are some pics showing the shape and fit.  The sheet would then be cut where the black outline is.  Then epoxied to the stock assembly, then finally altered to the correct size and shape.

Once that sheet is done, you move onto the next one....careful of the trade secret guardian though.

More to come.