I was on one of my other regular sites and noticed an article about making custom acrylic parts over the internet. It involves drawing up your design using free CAD software. Then you upload the image to their website. The website gives you an estimated cost, and shows you a 3D example of what you will get. Then you wait a couple weeks and the part shows up in the mail. I know it sounds simple, but check out this
presentation and decide for yourself. The site that makes the part is called
BigBlueSaw.