I have used a copping saw, utility knife and a dremel.
I use the utility knife to rough the shape.
I use the coppling saw with a new blade with the most TPI i can get to shape it further.
I use vaious grinding tips on the dremel to fine tune the shape.
Finally, i file, sand and polish the edges.
Sounds like an all day event but i am usually done in an hour.

Be very careful when drilling holes for posts. If the drill binds and pulls the bit thru you will crack the plastic.

Not that it matters when you want something but how much is the graphic artist charge for the plastics?
I would guess pricing would vary wildly from region to reqion and even by GA to GA.

That price seems fantastic to me.
I suspect it would be more in the Boston area but as i said when i asked, the price doesnt really matter when it is something that you want to complete a game.
I may look into this the next time around.
Thanks.