anyone have any good tips on building a cheap vacuum forming machine at home?

How large of a surface build area do you need?
What is your definition of inexpensive?
I teach technology at a high school and have a small vacuum former that is fairly cheap and good quality. It has a 10"x14" area but we have never done something that large. The total cost for the former cost us about $1000
 

I built one of these, works really really well.
But if you are looking to vac-form a transparent visor you may have difficulty. I couldn't get pet-g to completely cover my buck for my guy-man visor, just couldn't get the suction. it pulled about 95% of the way. ended up getting it done professionally.

If you are looking for a one off, you might be better going to speak to a local professional, if you ask really nicely they might do a one off pull.

This system works amazingly with styrene though, so it wasn't a complete waste.
 
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