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First I am using .40th thick thermal plastic. When I get done, some parts are less then .10th thick. I do end up making several parts to get the right draw on them For the pumpkin I used a deep tube for the female mold. This has a lot to do with the depth of the parts. I am finding with the more I work with the molding process I can get more complex shapes depending on the male mold(Tide stain stick cap). This is really the only thing that limits me, the male mold parts. The one thing to remember is that with the thermal plastic you get it right the first heating since it will not heat a second time. With practice you can make anypart you need this way. I am still looking for how to do the inner fenders ont he front since the shape does not fit anthing I can find. I hope this answered the question adaquately, if not let me know and I can go into more detail with photos as needed. 
Thermal plastics are used mostly in vacuum forming of parts like boxes and packaging of parts. I learned about this from my borther,who hold most of the patents on vacuum forming methods and machines. I have helped him out building machines and watched as he designed new ways of forming parts. Granted I dont have anything like the budgets he would have and do everything with simple parts and an exacto knife,a few files, and sandpaper. Everthing is made in a space of less than 2 square feet on my desk.
I hope that the methods I use can be helpful to others in making some parts to augment the kits most people use.
Again thank you for the comments and questions. They help me in coming up with new techneques to make more elaborate parts from nothing.
Kenn
Edited by kennb, 13 February 2013 - 06:11 AM.
