Just a note on vacuum forming to folks who might not understand the full
process.

The process of vacuum forming itself is relatively simple but also has many
limitation of what can be made. Tooling can range from simple to very
complex and though the cheapest of all plastic processing, can get expensive
and if it isn't made right your parts are scrap.
When you do make a part, it is usually the post-processing that can get
quite complicated and expensive. Parts need to be trimmed out of their
plastic prison, sometimes this can be done by hand or with cutting dies,
thicker materials must be machined out. If there are any holes, slots or
cutouts required, CNC machining is a must for accuracy. A vacuum fixture,
much like the mold, is used to hold the part for machining, which are
usually done one at a time.

Being able to splash a part for a mold is not the hard part. It's finishing
your molded piece of plastic that's the hard part.

Note: it is sometimes possible to make cutting templates to trace cut lines
to your part and then with skill and grace, trim and finish the part with a
dremmel tool or router. This process is extremely tedious and is useful
mainly for making a prototype or two, not dozens.

Good luck with it!

-Steven Dodson
Kneeland, CA
"Inga" the 87 Syncro