Today in class I finished the vacuum form project. I had my MDF cut-out from last class sanded and ready to go. I bought two pieces of 40 mil. styrene and after waiting in line for a reasonable amount of time I was able to vacuum form my two pieces seperately. Luckily I got everything right the first time. I then used a straight blade very carefully to score the edges and broke the styrene along my cuts. I sanded them flat, with the MDF still inside, with heavy grit paper and then used a much finer grit later. I inserted the inside support structure, tacking weld-on and clamping it as I went. I connected the two pieces slowly and applyed weld on liberally. I did not need to use putty at all. Finally, I gave it a finish sand along the seam. Overall, I'm very happy with the way it came out.
