Are you going to California Extreme? I could help you get a cast. PM if your interested.

Np anytime. I'd suggest casting it with a 3 (maybe 4) part mold, cap a piece of the PVC and clear tape one end near the inside top, split the mold it up the side 50/50 lengthwise. I would make the mold out of Smooth-On Rebound 40 which you can pick up at Reynolds Supply there in LA. A 2lb kit should do it. I'd cast it in Smooth-on 65d. Smooth-on has a lot of video's on casting and molds. A quick watch of any of these should get you there in no time.

My guess is with some foamboard, a bit of clay, and a hot glue gun we could knock out a mold in an hour or so.

Sorry, would actually recommend rebound 20 vs 40. 40 is a a bit stiffer, think eraser vs rubber band, and that will help with de-molding.

Isn't there worry that when the clear does start to degrade or flake it will largely go un-noticed until it gets to the color, by then the clear will work like a mild abrasive?

I'd be interested to know if that actually is a problem or one I'm imagining.

I'd like to pearl or flake and maybe dye a ramp or two. I was thinking of doing it just on the back. Still transparent but a bit more pimp.