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The only thing that can save us is the open source Maker movement. Sorry to hear about your problems, of course. You had what, $250, in the vacuum forming tool?
Since I can get 4x4' pieces ~1/8" thick for $5, my plan is to find a form that's 36" in diameter with 2-3" of crown that spins on it's center. Then I can rent a bank of heat lamps and bake it like one of those open air pizza cookers. Apparently you can weld ABS to ABS with a soldering pen, or acetone.
Cut it in half tip to tip and cut 2 of the 3 tips off each triangle and trim to final curve.
Still thinking about the hardware. 1/4 turn cam-locks?
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