[Roo]

I spoke with a TAP Plastics store manager about this project, and he brought up a few things which may/may not help.

1. The lexan, when heated past 212 degrees, becomes VERY moisture prone, and will absorb moisture, which is what causes the bubbling.

2. The lexan may/may not melt, given the temperature of the halogen bulbs and the heat that is created...which is obviously how you're forming these in the first place. If you use thicker Lexan, it would simply retain more heat than thinner Lexan, but would last a bit longer before meltdown occurs.

Again, this is the opinion of a guy who's been doing plastics for some time now, and is only meant for informational purposes. I'd like to see you succeed, and would be happy to purchase a set of these when they become available.