[Coach Norm]

Andrew,
We used ABS from Regal Plastics here in Austin. I am sure you used them when you were here in Austin. They actual had some 13" wide x 8' lengths that they gave me at a very good discount price. We used it for the skirt of our robot last year. It was haircell (textured on one side).

We heated it using a heat gun. It was very easy to accomplish using a workbench and scrap 2" x 4" boards. If you have ever heated and shaped PVC, it is very similar in process.

The only problem we had was we design it to attach to the chassis with one inch tabs by riveting. We did experience some problems with the tabs breaking.