I have about 27 different personalities in my single body. When I speak of “We”, I am referring to my one body containing all 27 of us crammed in here. Research the “Babushka Dolls” of Russia.
I've done some forming with polycarbonate (trade name Lexan). Mostly cones, rings, and blast gates for dust collection systems. Best is to use a form and get the material to "slump temperature" in an oven. A heat gun will work if you're careful. A torch is too hard to maintain an even temperature because too hot and you'll get small bubbles in your material. You're working with a small window between bend and bubble. If you've a toaster oven do a test by placing a piece of poly over a block of wood and heat it until it slumps. Should slump at around 375-390ºF.
G'day Chrome, definitely fibreglass the window holes, especially as they are going to be painted anyway. What effect would the paint have on the Perspex and if they break they would have to be re-made and repainted, also possible water leaks. Looking forward to the see the build.
The easy way to do that Chrome is to take the existing bad window, apply tape over the outside, lay the new window over it and tape it in place, and heat it up with a heat gun, not a torch, and let gravity do the work. This will give you the precise look you're looking for. That's what I do when I need to replace boat windows. I use 1/8th or 1/4" acrylic too.
@@mikeh524 that would be the ideal way to do it. But then you have the expense of another machine. I'm just thinking about the DIY way, and when I do boats, I'm typically at the docks.
Chrome, there is a company called Plastec in Langley that does vacuum forming at a very reasonable cost. I used them a number of years ago. You will want to use polycarbonate because it has much better inpact resistance than acrylic.
Chrome use a face shield for that grinder. Also, a respirator wouldn’t hurt, but a face shield is an absolute necessity that’s the most dangerous piece of equipment in any shop the blades can break apart and possibly kill!
I really love your enthusiasm. Just taking a grinder and start grinding. I am really curious what you going to do with that van. One thing is for sure. It’s going to be amazing
I used to work for a large school district. There are companies that make custom lenses for fluorescent lights that may be able to help, but they're not cheap. I used to make wraparound plexiglass guards for exit lights by clamping the short edge to a table and sweeping a heat gun back and forth until the rest started to droop. They came out beautiful with a little practice. Polycarbonate can be bent in a sheet metal brake. Be gentle or it will crack.
Those windows aren't a worry at all.. I made a home made adjustable brake press for acrylic just for one custom espresso machine I was putting together. Those bends were 90 degrees
Biggie is too cute. Can’t remember the other pups name but how much she has grown!! The windows, I have no clue other than plexiglass. Have fun figuring things out. 😎🍻
On the windows... you could also put fiberglass on the top section and leave just a rectangle-ish part to fill with glass... easier to get cut. It would still give you light at the bottom.
Make a template out of wood. Make it slightly smaller factoring in the plexiglass thickness. It should have the exact bend and rounded edges that you want. Leave a little extra then trim it after. Take your time with heat gun. Any bubbles or colour changes means you are too hot. Maybe start with a small piece and see if you can get it to bend over the edge of a 2x4 first
Very clean garage shop setup always wanted one never to late, might have to borrow your ideas. Great videos always fun to watch thanks for sharing your amazing idea with the new van really really cool can't wait. 👍🙏💪
Nice that's a 7.3 those are pretty bullet proof. While you have engine out get amsoils bypass filtration setup on this van that way oil stays nice and clean for those injectors cause if I'm not mistaken oil pressure is what pops the injectors for fuel on the 7.3. Also while the engine is out you may want to look at high quality steering boxes that don't have alot of play in them. Most 7.3 trucks have like 1inch to 2inches of steering wheel play alot of that comes from the gear steering box. Do your research there is a few aftermarket rebuilding companies that improve the tightness of the steering.
Maybe the best of both. Fill the top to the body line with a template from the bottom edge. You would have an area to install a flat window. Much easier to fab and seal.
I'm usually a guy that solves things like this around our shop. We would probably vaccum form an existing lense and then make a template to make lense from there. And of course you would get to keep the template in case more need to be made at some point down the line. It wouldn't be 100% accurate but it would be extremely close
Crome. Make a plywood templet of window with that top bend in it. Place a cutout piece of 1/4 inch thick plastic on a home gas or electric oven rack. Set oven to 170 to 180 degrees F. When plastic becomes playable, my oven took about 10 minutes, put welder's gloves on and place plastic over plywood mold. Bend top to fit curve of plywood mold with a gloved hand and cool plastic with other or use clamps to keep it bent for about 5 - 10 minutes, or until it sets up in new shape using a hair dryer set on highspeed cool. This process worked for me using Plexiglas plastic making a DIY 300-amp hour lithium battery box cover for my camper van.
You may want to consider painting the floor pans with truck bed spay liner instead of regular paint. It would make a seamless plastic liner under the carpet that wold limit the chance of water getting under or through the paint.
cool to see you pumped about this project!!! love you are including the grade 12 drafting class as well... greetings from langford/westshore area.. keep up the great content
Exactly as Brad said. I had same issue in UK. Had cracked & broken ambulance siren panels put in place of existing sirens when ambulance decommissed. I glued broken panels together & went over them with cut glass mat fibre glass & resin. Rock hard when cured then sanded. Pin holes filled with putty filler. Some panels were taken out & some were down in situ. Painted same colour as body. Looks hundred times better & blends in with body contours. Very time consuming but worth it.
Just something that came to mind when you fired the ambulance up. Make sure you get fresh diesel fuel in that tank every now and then. Diesel goes bad really quickly.
For a shower: Get two five gallon buckets..one for clean water from the hose and the other for the shower water to drain in. Build a platform and put a plastic tray on top with a drain hole so the water can drain in the shower water bucket.. then take it out and dump in an appropriate place if there is one..
Take the original lens, cast it in plaster, then cast a buck from the first cast, and you can form the replacement to match the mating surfaces the old one.
The ambo manufacturer may have drawings and schematics with measurements. They may even have it in a file format you can convert to whatever software those students are using.
Have you looked in to 3D Printing the lenses? There's a whole industry now for recreating old tail light lenses and side markers for automobiles. Maybe one of those companies can make your lenses.
Chrome , a couple of ceiling fans would help to get the heat back down to floor level. Or at least one in the center would be a huge help.. Just something to think about.
Too bad they don't make these windows anymore. I hope you find a suitable solution. I'm so excited about the ambulance project. Great video. I look forward to future videos.
Hey chrome, here’s an idea. Looking at your ladder on the side of your van you could hook up workout bands with handles to that and get a quick workout wherever you are.
Yeah, I agree with a lot comments... just cover the openings with metal and/or fibreglass. I assume this is a Demers ambo (I have one). You did a great job with your current van putting aftermarket lights - just do the same. As for the rust, good job but I just oil mine with a bunch of fluid film (once before and once after the salting season).
Hey chrome, that was an awesome video and that is true having the right tools makes all the difference. I cannot wait for your video with the high school from the US. With their drafting project, you and cruz always make my day guys be safe have fun.🇺🇸♥️✌️🙂👍🐾🐾🚐🇨🇦
Chrome you have the perfect tool to do exactly what you're trying to do you have a toaster oven set it on a low heat roughly about 170° put the one side where you're going to put the bend in it and let it warm don't get it hot fast but let it warm then put it on a frame where you want the crease to bend let it cool
I know they make clear plastics that can heat and mold. I suggest mounting lights in those pods so you can flip a switch and have exterior lighting wherever you choose to park.
Use a heat gun. But get some aluminum form it to the curve you want. Use the aluminium as a form for the window and heat the plexiglass and allow it to slowly relax and lay down on the form.
Not in Canada, however I had a cool idea if for whatever reason you see it and say YES! Do a stained glass window out of flexy resin. It would be cool... that's all.
Hello Chrome, I’m not sure what your plans are for the interior design but if it were mine I’d want to preserve those very unique light lens holes as windows. Even if they wound up being the back side of a storage cupboard they’d be a really nice light source… I believe it was the Gamble House in Pasadena CA that utilized a design for admitting light to interior spaces (closet and bathroom). Interior walls incorporated stained glass panels that allowed light from exterior windows to penetrate further into the home’s interior spaces… They’d provide great interior light while not allowing access both visually or intrusion… I did a search “bending Lexan” and found a website that describes the process which would be stronger than plexiglass. Also found a TH-cam video as well… Looking forward to seeing what the design turns into.
Try going to a automotive glass place like speedy they should be able to make custom glass and mouldings for you or weld em up. Oh yea dont forget to keep cruze away when grinding etc. 👍👍⭐⭐⭐⭐⭐🚐🐕👍👍
Really glad you are considering moving into the Ambo, would seriously think about making the roof higher. Might cost a bit and be a pain in the arse but will be worth it in the end
Chrome just a suggestion but if those cut out pieces will fit could you put them in your toaster oven to heat it and get it malleable to wear you can form it in the shape of the window. I know that’s how people do kydex plastic
Hey Chrome, don't measure the inside of your van in the traditional way. Use your IPhones Lidar scanner, scan inside of van, and then send that file off to your HS class. Just a thought....
Can I suggest a bit more complex option yet easier if that makes sense. How about fabricating a outter molding out of Sheet metal or even wood with the center cut out in a more easier to find shape and size. This would be an easy solution and much more customized end result. Otherwise you're going to have to get lucky and find something pre-made or mold injected and that's spendy. A molding out of metal or wood much easier and do like a stained glass effect type design in middle
Are you going to video visit with us when you visit with them? I asked the question as you spoke it.. but great minds think alike. Learning is a life long thing. Thank you Chrome. I have heard of some of these products that you spoke of. Lizard skin I'm familiar with. Some people are impressed with Lizard skin. I was not. Might have been where I had to sleep in my part of the interior vehicle that I had to sleep when it got used in a different project, though.
I had an old motorhome with the little windows high up by the ceiling and I loved the ambience they added. Why paint them black??? Then you could have an ambience ambulance. Best wishes on your project.
probably already been suggested but you could clamp a 2x4 down on your work bench and use it as a press-brake. heat it. line it up under the 2x4 n bend til its the angle you want.
Just a bit curious. Why does people often say "We" when they are "I" ? It's kinda strange.
WE = ME and my Dog CRUZ
@@VANCITYVANLIFE and us viewers who are all here with ya
Don’t forget Cruzie Bear!❤️
I have about 27 different personalities in my single body. When I speak of “We”, I am referring to my one body containing all 27 of us crammed in here.
Research the “Babushka Dolls” of Russia.
@@robgreenough1164 No. Emi has her own channel. When she says we she is referring to her and her cat.
Huge project the Ambulance . I know your anxious to get started but take your time. Enjoy the project. Will enjoy seeing the progress being made.
I've done some forming with polycarbonate (trade name Lexan). Mostly cones, rings, and blast gates for dust collection systems. Best is to use a form and get the material to "slump temperature" in an oven. A heat gun will work if you're careful. A torch is too hard to maintain an even temperature because too hot and you'll get small bubbles in your material. You're working with a small window between bend and bubble. If you've a toaster oven do a test by placing a piece of poly over a block of wood and heat it until it slumps. Should slump at around 375-390ºF.
G'day Chrome, definitely fibreglass the window holes, especially as they are going to be painted anyway. What effect would the paint have on the Perspex and if they break they would have to be re-made and repainted, also possible water leaks. Looking forward to the see the build.
The easy way to do that Chrome is to take the existing bad window, apply tape over the outside, lay the new window over it and tape it in place, and heat it up with a heat gun, not a torch, and let gravity do the work. This will give you the precise look you're looking for. That's what I do when I need to replace boat windows. I use 1/8th or 1/4" acrylic too.
Need to make a mold from the existing window. Then use a vacuum former.
@@mikeh524 that would be the ideal way to do it. But then you have the expense of another machine. I'm just thinking about the DIY way, and when I do boats, I'm typically at the docks.
Hey Chrome, any chance you will put a snorkel on? Now I think that would look cool and you will be able to drive through anything.
It's so nice to see you back at your shop. It's going to be a great winter.
Chrome, there is a company called Plastec in Langley that does vacuum forming at a very reasonable cost. I used them a number of years ago. You will want to use polycarbonate because it has much better inpact resistance than acrylic.
Chrome use a face shield for that grinder. Also, a respirator wouldn’t hurt, but a face shield is an absolute necessity that’s the most dangerous piece of equipment in any shop the blades can break apart and possibly kill!
😨
Amen!
Make sure you undercoat the entire van. FluidFilm is the way to go.
I really love your enthusiasm. Just taking a grinder and start grinding. I am really curious what you going to do with that van. One thing is for sure. It’s going to be amazing
I used to work for a large school district. There are companies that make custom lenses for fluorescent lights that may be able to help, but they're not cheap. I used to make wraparound plexiglass guards for exit lights by clamping the short edge to a table and sweeping a heat gun back and forth until the rest started to droop. They came out beautiful with a little practice. Polycarbonate can be bent in a sheet metal brake. Be gentle or it will crack.
Cool thing about the lizard skin is that you can still put the kilmat type stuff over it too.
Those windows aren't a worry at all.. I made a home made adjustable brake press for acrylic just for one custom espresso machine I was putting together. Those bends were 90 degrees
I just love Cruzie the Inspector. He'll make sure it's done right.👍❤
Biggie is too cute. Can’t remember the other pups name but how much she has grown!! The windows, I have no clue other than plexiglass. Have fun figuring things out. 😎🍻
Heat it slowly an bend it on the edge of the work bench . Old school off road stuff 😎
MAKE A MOLD ON ONE OF THOSE RED ONES, THEN POUR EPOXY IN THE MOLD. INSTANT WINDOW.
That is an excellent Idea. I am sure there are exposy people out there who could do it for Chrome.
Make mold then use a vacuum former
On the windows... you could also put fiberglass on the top section and leave just a rectangle-ish part to fill with glass... easier to get cut. It would still give you light at the bottom.
Make a template out of wood. Make it slightly smaller factoring in the plexiglass thickness. It should have the exact bend and rounded edges that you want. Leave a little extra then trim it after. Take your time with heat gun. Any bubbles or colour changes means you are too hot. Maybe start with a small piece and see if you can get it to bend over the edge of a 2x4 first
Very clean garage shop setup always wanted one never to late, might have to borrow your ideas. Great videos always fun to watch thanks for sharing your amazing idea with the new van really really cool can't wait. 👍🙏💪
So much cuteness with Cruz and Biggy!
Nice that's a 7.3 those are pretty bullet proof. While you have engine out get amsoils bypass filtration setup on this van that way oil stays nice and clean for those injectors cause if I'm not mistaken oil pressure is what pops the injectors for fuel on the 7.3. Also while the engine is out you may want to look at high quality steering boxes that don't have alot of play in them. Most 7.3 trucks have like 1inch to 2inches of steering wheel play alot of that comes from the gear steering box. Do your research there is a few aftermarket rebuilding companies that improve the tightness of the steering.
Maybe the best of both. Fill the top to the body line with a template from the bottom edge.
You would have an area to install a flat window. Much easier to fab and seal.
I use second skin damplifier pro. I'm a car audio fanatic and trust me, this stuff works amazingly well
I'm usually a guy that solves things like this around our shop. We would probably vaccum form an existing lense and then make a template to make lense from there. And of course you would get to keep the template in case more need to be made at some point down the line. It wouldn't be 100% accurate but it would be extremely close
Happy refurbishing,blessings and safe travel dear pal! 😀
Enjoy and take your time on your winter project
I say, if you are not using it for light, then make it seamless and use fiber glass and fill in the holes. Slick and cool just like you, Chrome! :)
Crome. Make a plywood templet of window with that top bend in it. Place a cutout piece of 1/4 inch thick plastic on a home gas or electric oven rack. Set oven to 170 to 180 degrees F. When plastic becomes playable, my oven took about 10 minutes, put welder's gloves on and place plastic over plywood mold. Bend top to fit curve of plywood mold with a gloved hand and cool plastic with other or use clamps to keep it bent for about 5 - 10 minutes, or until it sets up in new shape using a hair dryer set on highspeed cool. This process worked for me using Plexiglas plastic making a DIY 300-amp hour lithium battery box cover for my camper van.
You may want to consider painting the floor pans with truck bed spay liner instead of regular paint. It would make a seamless plastic liner under the carpet that wold limit the chance of water getting under or through the paint.
cool to see you pumped about this project!!! love you are including the grade 12 drafting class as well... greetings from langford/westshore area.. keep up the great content
Fill in those top window holes with fiberglass. Far less chances for future breaks and water leaks.
exactly what i thought ........we made a hatch cover for a boat out of fiberglass it was not that hard to do and was very sturdy
Exactly as Brad said. I had same issue in UK. Had cracked & broken ambulance siren panels put in place of existing sirens when ambulance decommissed. I glued broken panels together & went over them with cut glass mat fibre glass & resin. Rock hard when cured then sanded. Pin holes filled with putty filler. Some panels were taken out & some were down in situ. Painted same colour as body. Looks hundred times better & blends in with body contours. Very time consuming but worth it.
Hi Chrome. 3D printed Fiberglass does a prototype or even 3D Printing Carbon Fiber if you are interested in covering the hole.
Just something that came to mind when you fired the ambulance up. Make sure you get fresh diesel fuel in that tank every now and then. Diesel goes bad really quickly.
For a shower: Get two five gallon buckets..one for clean water from the hose and the other for the shower water to drain in. Build a platform and put a plastic tray on top with a drain hole so the water can drain in the shower water bucket.. then take it out and dump in an appropriate place if there is one..
Take the original lens, cast it in plaster, then cast a buck from the first cast, and you can form the replacement to match the mating surfaces the old one.
Before you start doing any welding make sure and disconnect the battery so you don't damage any electronics
The ambo manufacturer may have drawings and schematics with measurements. They may even have it in a file format you can convert to whatever software those students are using.
cant wait to see it done. i love that dog so sweet
Try a heat gun on that lexan bend on a form.
Check out a company that makes custom boat or motorcycle window shields. They have the materials, tools, & experience to work with plastic.
Have you looked in to 3D Printing the lenses? There's a whole industry now for recreating old tail light lenses and side markers for automobiles. Maybe one of those companies can make your lenses.
I'd so them clear and put insulation on the inside when needed that natural light would be amazing.
Chrome , a couple of ceiling fans would help to get the heat back down to floor level. Or at least one in the center would be a huge help.. Just something to think about.
Too bad they don't make these windows anymore. I hope you find a suitable solution. I'm so excited about the ambulance project. Great video. I look forward to future videos.
Hey chrome, here’s an idea. Looking at your ladder on the side of your van you could hook up workout bands with handles to that and get a quick workout wherever you are.
Yeah, I agree with a lot comments... just cover the openings with metal and/or fibreglass. I assume this is a Demers ambo (I have one). You did a great job with your current van putting aftermarket lights - just do the same. As for the rust, good job but I just oil mine with a bunch of fluid film (once before and once after the salting season).
Get some tarps to hang up around the ambulance for when you work inside to contain the dust.
I'm worried about the toxic dust on him and Cruzie
Maybe you can use a 3 D scanner it would be your best option to do.
Hey chrome, that was an awesome video and that is true having the right tools makes all the difference. I cannot wait for your video with the high school from the US. With their drafting project, you and cruz always make my day guys be safe have fun.🇺🇸♥️✌️🙂👍🐾🐾🚐🇨🇦
Chrome you have the perfect tool to do exactly what you're trying to do you have a toaster oven set it on a low heat roughly about 170° put the one side where you're going to put the bend in it and let it warm don't get it hot fast but let it warm then put it on a frame where you want the crease to bend let it cool
keep some in clear plexiglas (acrylic( or Lexan (polycarbonte) or frosted or tinted - maybe find a laser cutting shop in Van or the Island to do it
Sound proof on the inside of the ambulance firewall and floors would be best I think, away from the elements. Just prep the area well!
I know they make clear plastics that can heat and mold. I suggest mounting lights in those pods so you can flip a switch and have exterior lighting wherever you choose to park.
I'm excited to see this ambulance finished
You could also use the air chisel to split the rocker panel
Use Loctite rust neutralizer to prevent any small surface rust from turning into rust issues
Love watching your vids Chrome & Cruze!!💜🙏🏻💜
Use a heat gun. But get some aluminum form it to the curve you want. Use the aluminium as a form for the window and heat the plexiglass and allow it to slowly relax and lay down on the form.
Not in Canada, however I had a cool idea if for whatever reason you see it and say YES! Do a stained glass window out of flexy resin. It would be cool... that's all.
Dude great video. Can't wait to see that big girl on the road
Check with a marine window guy. Gone with the Wynn's had a similar issue with their catamaran.
Best way is to fit and bend a piece of sheet metal and weld it do all the old window openings
If you're painting it then just use fiberglass plus if it's thicker than less heat loss
Hello Chrome,
I’m not sure what your plans are for the interior design but if it were mine I’d want to preserve those very unique light lens holes as windows. Even if they wound up being the back side of a storage cupboard they’d be a really nice light source…
I believe it was the Gamble House in Pasadena CA that utilized a design for admitting light to interior spaces (closet and bathroom). Interior walls incorporated stained glass panels that allowed light from exterior windows to penetrate further into the home’s interior spaces…
They’d provide great interior light while not allowing access both visually or intrusion…
I did a search “bending Lexan” and found a website that describes the process which would be stronger than plexiglass. Also found a TH-cam video as well…
Looking forward to seeing what the design turns into.
Next time come to Texas to get your vehicle its awesome to not have salt damage lol great vid love the channel
Love this channel! But be careful when filling your diesel heater with open flame near🤝🖖🏼
Try going to a automotive glass place like speedy they should be able to make custom glass and mouldings for you or weld em up. Oh yea dont forget to keep cruze away when grinding etc. 👍👍⭐⭐⭐⭐⭐🚐🐕👍👍
I think the bending thing can totally work. Don't give up on it just yet.
I like the windows all tinted in black! No more red
U try putting the plastic in a small oven to make the full thing flexy and the gently pressing it against the van and into shape
Sounds like Chrome is starting a Van Life business. I think that's pretty cool.
I'm an old gal who is not normally interested in cars and rebuilds but this was interesting
Great video Chrome. Looking forward to the winter projects.
Really glad you are considering moving into the Ambo, would seriously think about making the roof higher. Might cost a bit and be a pain in the arse but will be worth it in the end
And you could lose those "windows." In the end, it may be a similar cost and workload.
Yes especially as we age this can become more important
Love you Cruz
OMG, Biggie is the cutest lil thing ever. So petite and chunky.
Put up a small shed for your bathhouse if they will allow it
@Kathy Paley I appreciate that but I'm going to have to decline lol
Boat refitters could make replacement windows for this. Check with Nordmanner Marine Service in Richmond, BC.
Use a 2 by 4 and a heat gun for making those bends
Chrome just a suggestion but if those cut out pieces will fit could you put them in your toaster oven to heat it and get it malleable to wear you can form it in the shape of the window. I know that’s how people do kydex plastic
Some thin wood. Clamps, a wet rag to get wood wet. Put in clamps and jig. Steam let dry bent woof to your radius
If you're going to paint over them, Then use metal and a metal break , much easier to work with.
It would be cool to have those windows as skylights but if your just going to paint them you might as well fiberglass them.
I think I'd do the lenses in sheet metal, easy to form then just weld them in. Looks like your going to do some welding in the lower body anyway.
Ceramicoat we use it on engines too works
Take them all out and fiberglass them shut. Cheap, easy, and long lasting... It will also give you more room inside without the guts.
Chrome look up Corroseal you paint it on rust and turns it black and kills it. then you just lightly sand it then paint over it.
I swear Cruz is just absolutely 💯 adorable
Laziest grumpy dog I have ever come across.
No, Fibergl & paint to look like they're still there, otherwise you'll eventually have leaks. You'll have to always worry about caulking.
Get you a pop up shower tent or hunting blind for your shower and you could shower almost anywhere
Chrome! We had an idea! Get it 3D printed. The windows at the top that is. Then you could get it done exactly how you want. You're welcome.
Hey Chrome, don't measure the inside of your van in the traditional way. Use your IPhones Lidar scanner, scan inside of van, and then send that file off to your HS class. Just a thought....
I was just thinking of something like that. So many curves and crazy shapes.
3d printing from scanned specs?
Can I suggest a bit more complex option yet easier if that makes sense. How about fabricating a outter molding out of Sheet metal or even wood with the center cut out in a more easier to find shape and size. This would be an easy solution and much more customized end result. Otherwise you're going to have to get lucky and find something pre-made or mold injected and that's spendy. A molding out of metal or wood much easier and do like a stained glass effect type design in middle
Dynomat is the best for the engine bay but it's awesome every where my friend. My brother and I had used it before in some of our cars
if u wanna paint over em use mesh & putty to cover windows
Are you going to video visit with us when you visit with them? I asked the question as you spoke it.. but great minds think alike. Learning is a life long thing. Thank you Chrome. I have heard of some of these products that you spoke of. Lizard skin I'm familiar with. Some people are impressed with Lizard skin. I was not. Might have been where I had to sleep in my part of the interior vehicle that I had to sleep when it got used in a different project, though.
I had an old motorhome with the little windows high up by the ceiling and I loved the ambience they added. Why paint them black??? Then you could have an ambience ambulance. Best wishes on your project.
probably already been suggested but you could clamp a 2x4 down on your work bench and use it as a press-brake. heat it. line it up under the 2x4 n bend til its the angle you want.