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Old 08-27-2012, 01:21 PM   #5 (permalink)
Sven7
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Something similar- if you have rather shallow draw you could probably figure out a way to vacuum form a piece of plastic using a large oven and a shop vac, providing the buck is designed properly (with plenty of holes). Split the aero cap into a few pieces to make and bolt them together later. Maybe do fiberglass for the majority of it and vacuum form a window with complex curvature.

Perhaps a powder coating shop or sculpture foundry would allow you to use their oven/kiln?
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