Lemme jump to the punchline: don't use Kapton tape anymore!
We've just wrapped up a nice group buy thing-a-ma-jig over on the MakerBot Operators' Google Group. Hammerhead suggested posting the file so others could follow suit, and so participants could fly the flag.
This is a plate of glass that goes directly over the aluminum heated build platform on a Replicator 1:
- 3.3mm borosilicate glass
- 230mm x 150mm, +/-0.030" tolerance
- edges seamed for safety