Forming the lexan was actually exactly the same process as bending the aluminum. Luckily for me there are a number of different buisinesses in my building, one deals with plastics a lot, so I got them to order up a sheet of .060 thick lexan and had them cut it into rectangular pieces of the right size. Then I took the pieces, traced out the cuts I needed to make and went over to the other shop that does custom rain gutters. He's got this awesome power hand shear that makes nice smooth cuts and can do curves. I used that to cut out the wheel opening and other small cuts, then used the sheet metal brake to bend it. Thin Lexan can be bent in a brake pretty easily unlike plexiglass which will crack unless heated.

Dallas