Instead of the ABS plastic sheet. Have you ever worked with Kydex? It is most known for firearms holsters. It is extremely durable but it can be formed into any shape with the heat of a hair dryer or more quickly a heat gun. You can even lay a sheet of it over top of something say for instance a pistol and place it in the oven and it will self mold to the exact shape of the pistol. Hence why it is so popular for holsters.
http://www.ebay.com/sch/i.html?_from...sheet&_sacat=0
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