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Old 08-30-2010, 04:01 PM   #4 (permalink)
Otto
Master EcoModder
 
Join Date: Mar 2008
Location: USA
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Try this:

1. YouTube for "PETG" and "vacuum forming" videos, see how to do this in your kitchen with shop vac, etc., for cheap.

2. Use convex (outer) surface of pizza pan as a male mold, and make some thermoformed/vacuum formed duplicates of clear PETG plastic. That's the clear plastic used in 2 liter soft drink bottles and all sorts of stuff we use daily. Other thermoplastics would work, but probably not as tough and easy to work as PETG though.

3. If you want matching color, spray the inside surface of the PETG pans. Comes out uber-smooth and professional looking.

Got good & reliable attachment method yet?

You could install for highway trips, leave off around town if wifey objects for aesthetic reasons. With clear, though, a casual observer would not notice the clear smooth cover over the stock wheels or covers. Brake cooling could be an issue in stop and go traffic, hence the suggestion for highway use at speeds where aero drag is at issue.
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