So I picked up a 5'x5' 1/8 Baltic Birch panel today and a couple strips of Trim Tech Plastic corner bead 3/4" round. On my way home from the Hardware store I stopped at the Dollar Store and bought some large sheets of poster paper.
When I got home I taped two of the sheets together and then taped the edge of the paper to the center line of the window. With the paper up against the window and frame I used my new
fiberglass roller to force an imprint of the frame into the paper. I cut the form in the paper out and traced it on to the 1/8" ply. I added 1 1/4" around the perimeter to allow for the frame of the window and to give my self some grace when fitting the final product.
For the rounded edges and the depth of the cover I am using plastic drywall corner bead. I plan on fairing out the slight ridge between the mold and ply with bondo or something similar.
So in an afternoon I have gone from raw material to some semblance of what the product is going to look like.
Needless to say I'm pretty happy with progress so far. Although I think I have come to my first road block. The CORNERS.
Hmmm Perhaps if I use the bucket I used to draw my radius my corners as a mold I can make some strips of
fiberglass to fit the corner.
Any thoughts?