It was written...
   *Secrets of
Building a Plastic Vacuum Forming Machine* may also be a
 good book
 for the shelf. 
http://www.lindsaybks.com/dgjp/djgbk/vacf/index.html 
 I'll have a look, thanks!  One of my goals is to stick with technology we
 can (theoretically at least) do at home with a minimal investment.  If I
 spend a ton of time buying or building equipment, I start to feel like I
 need a business plan :-/. 
 
Ok, total neophyte input here on my part. But most of the techniques I've
seen involve doing the casting inside a small dixie cup. If the problem is
air bubbles, what about using a common (at least back in the 70's) device
that many people still have in their kitchens... a "seal-a-meal". Mine has a
vacuum attachment, to suck the air out of the container. So what about
putting the cast inside a mason jar, to which you've hooked up the
seal-a-meal (or maybe the backend of an aquarium pump) to suck out all the
air and let the cast set in a vacuum?
Maybe a nutball idea, as I haven't a clue about this stuff. Just a thought.
Jay