nice job and an easier method in terms of making the plastic itself would be to use a small router and/or router table as making clones from templates is done all the time in wood working. these are tools not everyone has of course but they're still commonly owned by hobbyists so another option would be to pay someone or get a friend to help. there are some caveats such as the original plastic needs to be as flat as possible and if the plastic is broken then that would need to be handled first. essentially all you do is fasten the original plastic using double stick tape to the new acrylic, lexan, or whatever, and install a pattern bit into the router and make as many copies as you want. the router bit has a bearing that's the same diameter as the cutting portion of the bit. the bearing rides along the edge of the original and cuts the copy out of the new material. to me, the hard part of plastic repro are the graphics.