Clean lid for aquariums

[Reef Pilot]

Originally Posted by SpateD

How would you bend the flange? Do you have any pictures of this in action?

I use lexan for a lot of things. Here is sock holder I made for my sump. This is probably the most difficult with multiple bends that are close together.
http://www.canreef.com/vbulletin/sho...921#post859921

Various methods can be used, incl sandwiching lexan between two straight edge pieces of wood in a vise. Or can use a rubber hammer over wood. Easier to make the bend (more leverage) before cutting the end off the lexan piece.

Trick is to use the thinnest lexan material you can find. It is light, has good light transmission, and holds its shape after a bend. It is very similar to forming thin sheets of aluminum and other metals. I learned this from building airplanes. As you know, airplanes have to be strong, but also very light. A straight skin only has strength in tension. But a skin with curves and flanges also has strength in compression. That design allows you to use the lightest materials for a given strength requirement.