Body building polycarboate vacuum forming

[nativepaul]

I think paralysed's link with the solid MDF is about right and probably the cheapest way to do it, I wanted to make a scale Bowler Wildcat body for my buggy, found a RC body maker willing to do short runs and made a wooden body from 3/8" mdf but when I took it to him he said it wasn't sturdy enough, he explained that he pulls over 6psi vacuum which over my roughly 2 square feet of body is the equivalent of parking a small car on top of it and my mould would crumble into fragments instantly, I suggested I could fill the inside with plaster of paris to make it solid and he was still dubious about it being tough enough for lexan although it may be enough for an ABS body which doesn't need as much vacuum, unfortunately making it from solid is a lot more work to add to the work I had already done making the hollow body and I am lazy so the project fell by the wayside and I ended up buying a WRC focus body for it.