RE: Vacuum forming
There is a company named Nor-Ray Products in Wichita Falls, Texas who does a super job of vacuforming on a one off or multiple copy basis. He's not cheap, but does great work. His phone number is (940)692-4475, but may be hard to contact as he is semi-retired and travels a lot. I've had him do several canopies for me, but he is very particular about the plug material, but does a fantastic job and a fairly quick turnaround time depending on what he has in the works at the time you order.
Good Luck with your project.
Les Morrow