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speaking from experience, vaccum forming is not just that easy. i do a lot of vac forming with a expensive vac machine. the drawback to vac formers is doing molds that have undercuts. such as side mirrors. when the plastic is sucked around the car, it will also go around the side mirror, thus locking the mold in place. sometimes you can get them out, but sometimes you break the plastic. also if you are going to vac form the current bit bodys, you will have to shorten them about 2 mm so you can mount them directly to the tabs. and you will also want to putty in the wheelwells, to avoid undercuts and locking in the current bit body...
for homemade vac kits the thinner the plastic/lexan your using the easier things will be. your best bet would be on .010" thickness or possibly .020" anything much thicker and your home made vac may not have enough power to suck down the thicker plastic.
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