by EJFoeth » Tue Feb 22, 2011 4:20 am
The radius of curvature for this 4.3mm x 2.61mm window is very small, so small deviations won't really show. Anyway. I'd start making a sanding template from brass strip/plate (not too thin! 0.5mm or so) and get one corner as nice as you can make it. To check: make an outline on paper with a pencil, flip the template, repeat: should be the same line, not necessarily circular, but still. Have two strips glued on the template 4.3mm and 2.61mm from the sides as a strop. Use the depth probe of a caliper to get the measurement down accurately. Start with the strip 2.61mm from the side. Make it a few cms long (err, inch) and measure at both ends to make it paralel. The other strip can be long as well, just make sure the end is a nice 90-degree angle and glue to the right position along the other strip. Use the same material for the strips as the windows so the new part is flush and you can hold the part (to some degree, you might need tweezers, pliers...). Glue from the rear of the strips or clean the template by scraping out excess glue. The position of the window against the strips is then the same for all windows in all positions. You can also use the template to sand all the windows to the same size.
Then just carefully sand away with wet & dry sanding paper and be patient

You only have to spend time on one good fillet... even if the fillet isn't exactly right, it will be equally wrong for all windows and that doesn't show, except on pics of the model and ship in one frame with arrows pointing out your sloppy work. So don't

The radius of curvature for this 4.3mm x 2.61mm window is very small, so small deviations won't really show. Anyway. I'd start making a sanding template from brass strip/plate (not too thin! 0.5mm or so) and get one corner as nice as you can make it. To check: make an outline on paper with a pencil, flip the template, repeat: should be the same line, not necessarily circular, but still. Have two strips glued on the template 4.3mm and 2.61mm from the sides as a strop. Use the depth probe of a caliper to get the measurement down accurately. Start with the strip 2.61mm from the side. Make it a few cms long (err, inch) and measure at both ends to make it paralel. The other strip can be long as well, just make sure the end is a nice 90-degree angle and glue to the right position along the other strip. Use the same material for the strips as the windows so the new part is flush and you can hold the part (to some degree, you might need tweezers, pliers...). Glue from the rear of the strips or clean the template by scraping out excess glue. The position of the window against the strips is then the same for all windows in all positions. You can also use the template to sand all the windows to the same size.
Then just carefully sand away with wet & dry sanding paper and be patient ;) You only have to spend time on one good fillet... even if the fillet isn't exactly right, it will be equally wrong for all windows and that doesn't show, except on pics of the model and ship in one frame with arrows pointing out your sloppy work. So don't :thumbs_up_1: