To form lexan - get your shape somewhat on with clay, smooth it to the perfect shape with plaster, bake-harden it.
When you've got it perfect as a positive image of what you want (do not use a negative, you'll end up with undesirable side effects) lay your lexan on it and bake it @ 200* - 300* until it forms properly.
After it cools, you may need to polish it up a bit.
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"¿ʞɐǝɹɟ ɐ ǝɹ,noʎ uǝɥʍ 'ʇı ʇ,usı 'ʎlǝuol s,ʇı"
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