I'm going to go way out here...
Does anyone have any experience with vacuum forming?  I have several sheets of ABS plastic with haircell texture on one side.  I would like to produce a monitor bezel for the CRT PC monitor I decased.
I've read about it, and I have a process in my head that I think will work.  However, it certainly seems like a LOT to bite off.
Anyone tackle something like this before?