This is me entry for t' EMRR's Reusable tip contest. I always wanted t' build a vacuum formin' machine and t' Retro Spaceship Contest was just t' motivation I needed. Aye aye! After surfin' t' internet I found a nice inexpensive design by Ralis Kahn (www.halloweenfear.com/vacuumformintro.html). Ya scallywag!

My goal was t' build a vacuum former for less than $50. I modified this design by eliminatin' t' heatin' element; I substituted our family oven. Blimey!

Here is what you need:

• 1 - 13" x 19" Heavy Duty Cookie Sheet
• 1 - 13" x 19.75" x .25 plexi-glass sheet
• 1 - 2.5" PVC 90° Elbow
• 4 - 6" x 1-1/2" Aluminum Angle Iron pieces
• 2 - 11.5" x 11.75" x .75" laminated particle board pcs
• 2 - 19.625" x 11.75" x .75" laminated particle board pcs
• 2 - 5/16" x 8' screen frame material
• 8 - Plastic screen frame corner pieces
• 8 - Large paper clips
• 1 tube silicone caulk

Start by drillin' 1/16" hole in one corner o' t' cookie sheet and continue drillin' 1/16" holes 1 inch apart over t' entire surface. Well, blow me down!

Next, me bucko, drill about 2" hole in t' center o' t' plexi-glass sheet. Then glue t' PVC elbow over t' center o' t' hole so that t' elbow is pointin' out toward one end o' t' plexi-glass sheet. Begad! Blimey!

Next, assemble t' particle board into a box usin' t' aluminum angle iron. Cut a clearance hole or slot in one end o' t' particle board box for t' shop-vac hose. Avast! Blimey!

Now test fit t' box, shiver me timbers, plexi-glass sheet, and cookie sheet. T' slot in t' box should align with t' elbow mounted t' t' plexi- glass. Aye aye! Mark and drill t' mountin' holes through cookie sheet and plexi-glass into t' box.

Next put a thick bead o' silicone caulk on t' edge o' t' cookie sheet then lay t' plexi-glass sheet over it makin' sure t' cookie sheet and plexi-glass seal. Ya scallywag! Mount this assembly t' t' box.

Finally, shiver me timbers, assemble t' 2 screen frames makin' them slightly larger than t he cookie sheet.

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Operation is pretty simply. Ahoy! Clamp a piece o' plastic (polystyrene, ABS, etc.) (thickness is your choice) betwixt t' screen frames usin' t' large paper clips t' hold t' frames together. This assembly should be heated. I used our oven at 375° for about 2 minutes. Begad! With t' shop-vac attached t' t' PVC elbow, turn it on and place t' master onto t' cookie sheet. After t' plastic is heated smartly place it over t' master pushin' all t' way t' down until it contacts t' cookie sheet. Blimey! T' vacuum will then take over. Once t' plastic begins t' cool; turn off t' vacuum and carefully remove t' master.

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