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Starting Member

United Kingdom
2 Posts

Posted - 02/02/2017 :  10:24:01  Show Profile  Reply with Quote
I am currently designing the body of recumbent bike similar to that of the velomobile, which is a college project. I'd like to ask members what is the cheapest and easiest method of obtaining a curved windshield similar to the Velomobile's, which can be made to fit my design which is very similar.

Also, for a diy project, obviously with access to the universities tools etc, what method is cheapest in creating a mould for the velomobile's body?

Much appreciated!


Garrie L Hill
human power supergeek

1805 Posts

Posted - 02/02/2017 :  11:32:32  Show Profile  Reply with Quote
We need a bit more descriptive information before helping you. When you say, "...easiest method of obtaining a curved windshield similar to the Velomobile...", do you mean a "flat wrap" or a true 3D shape? Flat wrap would be like taking a sheet of paper in the shape of a trapezoid and bending it in 2D only. True 3D would be like a segment of the surface of an egg shell.

for shell design http://www.recumbents.com/wisil/hpvshelldesigner/

Then CNC the mold. You might email the University of Toronto team for tips. Here is their site

AND look through the various design/build projects we have been doing for 30+ years

Garrie "carbon based lifeform" Hill
HPRA Co-Dictator of the East
for pics of some of my time and money sucking projects
and videos

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Starting Member

United Kingdom
2 Posts

Posted - 02/03/2017 :  04:07:10  Show Profile  Reply with Quote
Thanks for the reply. Yes, a true 3D shape.

Thanks for the links, help a lot.

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human power supergeek

1059 Posts

Posted - 02/03/2017 :  07:19:46  Show Profile  Visit carolina's Homepage  Reply with Quote
you should only use cell cast acrylic

If its laid in a mold to kool, must be a female mold.

There are some youtubes.

An oven can be built from doubled up celotex insulation sheets 4x8..

Hang two eye electric burner at roof of oven pointing down.

warm at 320 for 10 mins . & lay into female mold. (oven mitts needed of course).

acrylic can only lay on 100% cotton when warming in the belly of the oven.

glue into your carbon frame only with urethane/never silicone.

cell cast acrylic is 65$ for a 4x6 foot sheet, they will cut in half here.

some say put fan in oven/not needed.

You prob should make a plug and then a mold (you can sell windscreens) to do it correctly.

Iam a pilot, a friend of mine (todds canopies of ft lauderdale fla.) got killed in his plane few months ago. He taught me what l know, shame hes not still around. Makes me sick!

I will be doing this process above explained in few months.



Edited by - carolina on 02/03/2017 07:21:34
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recumbent guru

554 Posts

Posted - 02/03/2017 :  09:01:09  Show Profile  Reply with Quote
The acrylic will likely be cheaper than Lexan. It is a classic make or buy decision. Look for shops that make sailplane canopies or motorcycle windscreens. If the university does have a CNC vertical mill you are set, if not check a trade school. They will need specific dimensions at incremental depths to program the tool path for the mold. Some folks use vacuum to draw the material down over a male form.

Edited by - Grant-53 on 02/03/2017 09:03:08
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