The edges are 100% infill and about 4-5mm. I didn’t have any deformation around the edges of mine, mainly in the center where the infill was like 20% and the wall thickness like 2-3mm.
The key is to work fast and cool quickly. Have a freezer towel or something really cold to cool the sheet quickly. Also if you have sharp transitions in the mold drill a small pin hole for vacuum in that area (like corners).
First attempt at vac forming today.
3mm styrene sheet formed over a buck and the deck to get matching concave on the flange.
Very nice! Are you going to use that one for a mold so you can get the concave shape on the next buck? You could probably save some space and material that way.
Yeah considered that. Might do. Really just a test of the heater setup and vac former first. Went pretty well after I removed the tilt switch from the heater I used. Haha.
Spent minimal time on preparing the buck which was just repaired from one I broke when I made a vac bagged carbon enclosure. Covered in packing tape which actually showed up on the vac formed part which was a surprise.
Probably remake a smaller frame to just cover the board and save material and make a new enclosure buck with a new shape.
Anyone have experience using vac formed parts as a female mould for fibreglass or carbon enclosures? If I hit the mould with release wax and pvc is a carbon layup going to release from it?
Result.
Harder to cut neatly than expected. Melts easily. Best result with score and snap. Followed by hand held electric planer. 
Really like what you have done here, seems like the best way to get a perfect fit and seal.
I wish I had the space for a vac former that large.
Just to revive this thread real quick, I am currently working on building a vacuum former for my enclosure.
This is it so far 
but hopefully it comes together. After seeing your results @rosco i wish I had made it big enough for the whole deck. As is, my plan is to use a heat gun to shape the flat flanges of the enclosure to the deck.
I bought some 3mm ABS sheets, and I plan to fabric skin for strength, and to match my board. Im glad I found this thread haha, I dont plan things ahead very much I just go for it and try to figure it out on the way.
Wish me luck!
How did this end up going? My new neighbors are cool with expanding the shop in the garage so I may have room for one finally.
I abandoned the vacuum forming because I couldn’t be bothered to make a heating chamber for the ABS sheet. I ended up making the world’s shittiest buck and using a heat gun and clamps to form the enclosure bit by bit. It turned out really shitty and I scrapped that build because of it 
Moral of the story, prep work is everything. If youre like me, and are not willing to put in the prep-work, then just buy an enclosure from @BigBen haha
I’m working a 1500w ceramic heating element into an appropriately insulated thermoplastic oven.
I found large sheets of of 0.118 inch Kydex V on Amazon.
I’ll post if It works, eventually.
Just found this Thread!
We are on a very similar mission. Fired it up the first time a few days ago.
Result was quite shitty but now I know I need to work on better heat distribution.
If only 1000x500 mm² ABS was cheaper I could test a lot faster to iterate. Know I’m stuck with overthinking instead of spending money 
