Good way to make square windows

Trekmanscott · Post by **Trekmanscott** » Wed Mar 09, 2005 1:23 pm

Hi all,
I'm planning a new project. I would like to light the ERTL Cardassian Galor class. I think i've got a handle on the lighting part. However the Galor has a lot of rectangular windows. Does anyone have any tips or suggestions on how I can get consistant windows.

Thanks!

M.T.C. · Post by **M.T.C.** » Wed Mar 09, 2005 1:41 pm

I would probably try to take a micro drill and drill smal holes where the windows are,and maybe use fibre optic lighting to light them.Unless you are wanting the windows to stay rectangular,then I would drill holes and take an exacto blade and try to carefully cut each window to its shape,but it will take quite a while to do that.Hope that helps.At least that is what I would do,maybe someone has a better suggestion.

sbaxter · Post by **sbaxter** » Wed Mar 09, 2005 2:59 pm

I used a small "jeweler's"-type flathead screwdriver. I heated the business end with a candle flame and just pushed it through the plastic from the outside. It worked pretty well with a just a couple of minutes of practice. I won't pretend the edges were square, but they were closer than I would have gotten with a drill.

Qapla'

SSB

Warped Speedster · Post by **Warped Speedster** » Wed Mar 09, 2005 9:33 pm

First drill your starter hole. Then you can use a tiny square file to help turn the round hole into a square hole by slowly pressing it (forcing it)through. Then extend it into a rectangular shape. Then true it up with an exacto blade if need be. It's a slow tedious process and not easy to do but it will even get it done.

sbaxter's hot screwdriver method is an interesting idea too.

rocketrider · Post by **rocketrider** » Thu Mar 10, 2005 1:45 pm

I have not tried this yet, but im thinking it might work depending on the thickness of the plastic (and assuming its not resin.

If you purchase a piece of square brass tubing as close to the size of the window as you can get. File the four outside edges of the end of the tube to create a "die" and using a wood block backing, gently tap the windows out.

If anyone else has tried this and has had problems let me know.

Like I said, I have not done this proceedure with models, only in my graphic design business.

Glen W

macfrank · Post by **macfrank** » Thu Mar 10, 2005 2:58 pm

williamson wrote: If you purchase a piece of square brass tubing as close to the size of the window as you can get. File the four outside edges of the end of the tube to create a "die" and using a wood block backing, gently tap the windows out.

I think this would work, but I haven't tried it on plastic. I've seen it done on thin brass, to make occultation disks for a telescope camera (to block out a star's image).

Also, wouldn't you would want to file the inside of the square brass tubing instead of the outside? This would keep the cut square and even.

big-dog · Post by **big-dog** » Thu Mar 10, 2005 8:30 pm

Go to any craft or scrap booking store and buy a punch. You can punches of almost any shape you want. You'll have to brace behind the piece, but that's the way I'd go, unless you want to square off a coupla hundred round holes and try to keep them actually square.

Chacal · Post by **Chacal** » Fri Mar 11, 2005 8:22 am

You could even mix the suggestions: get brass tube (square, rectangular, the shape of the hole you need), heat it up...