You're obviously the expert, but what I was thinking of doing was:
1- taking measurements off the mesh
2- drafting it in solidworks, print out paper inserts and test fit. Re-size/ re-print until I have pieces that fit perfectly
3- have a piece of polycarb or acrylic lasercut (the machine shop I used told me that waterjetting can cause chipping on edges, etc and won't come out great). Will have it cut in a thin enough material that will allow for rigidity and flexibilty to make the slight curvature without having to vac-mold it
Let me know your thoughts, I don't have a background in this so there may be something I'm glossing over
Here is (as far as I know) the only other person to attempt this besides MaineLotus.
http://www.lotustalk.com/forums/f92/ridgemans-clear-covers-finally-24004/
He had his vacformed and looked like it cost an arm and a leg ($1000).. Wouldn't cutting a flat piece and curving it save unnecessary complexity?