[bkozlow]

Lexan is the only way to go. Have a professional plastic former do it. Most don't like to do Lexan because of the extra work involved but they are out there. You said, you have the form almost done, to do it properly you need TWO molds. You form the Lexan between the molds, if you think you are just going to lay the plastic on or in a mold and have it retain its shape as it cools you will have a complete new learning experience ahead of you. Professional molders use a liner of some type in the mold to reduce imperfections, find out what they use. The molds, I use are made of fiberglass and your wife's oven isn't big enough for what you want unless you have your own a pizza oven. If you can't find anyone, let me know and I will give you the address of the people I use in FL but look local. Their Lexan over Plexiglass was about 20-25% higher but in my opinion well worth it.

BillK