Posted for "Jeremy Fisher" <jffisher@gmail.com>:

 Angier,
 
 I made lenses for landing lights using the leading edge of the wing as a
 mould.  I used plexiglas from Home Depot cut to a manageable size (not the
 more expensive Lexan).  I then temporarily screwed two pieces of wood to
 opposite edges to make it easy to handle, heated it in the oven (to around
 320 degrees if I remember correctly) until it softened, then bent it over
 the leading edge.  Put a piece of paper over the wing to protect any paint
 from the heat.  You have to play with it for a few times to get the knack,
 but it worked out well.  I then cut the lens out with a Dremel tool.  The
 plexiglas is cheap so you can afford multiple mistakes.
 
 Jerry Fisher