Full face visor how to

I made a full face visor yesterday afternoon. I posted some pictures on my profile but some people asked me to make a how to thread and here it is...

step 1) Get your plastic with its desired thickness (perspex, plexiglass, anything else you an get a hold of). I used plexiglass which was 4mm.

step 2) Make your template and trace it onto your chosen material.

step 3) Cut out your plastic (I used a jigsaw with a very fine-toothed blade).

step 4) sand the edges smooth with a fine sand paper i used wet and dry (not sure how fine but it was fine).

step 5) Now this step might change for you because i used a proper plastics oven... I heated it on 175 °C for ten minutes. While this is happening pull off the protective paper.

step 6) After the tenish minutes i turned the oven down to 150 °C and put the visor in the oven.

step 7) I can't stress this enough: CHECK THE VISOR EVERY FIVEISH MINUTES. If the material starts bubbling it's too hot and it's now useless.

step 8) I pulled it out after about 15 minutes and it was soft and easy to change the shape.

step 9) I had a buddy help me here. Place the material over your helmet making sure it all aligns and hold it there for 5-10 minutes. Use your (gloved) hands to press the curves and hold them in that shape until it cools.

step 10) Line it up and mark where the holes need to go.

step 11) Drill your holes (I used a drill press) but any drill should do fine.

You should now have a visor.

Tips: 

• Don't take the protective paper off until you are about to heat it up.
• Use a fine toothed jigsaw blade and keep the speed slow.
• Let it get hot but not super super hot just a workable temperature.
• Use two people if you can.

Here are some pictures..