I used the standard sheet of lexan you can get at home depot for like 3 or 4 bucks.
I have scans of both plastics from (now defunct) ballsofsteel.
Anyone who wants those scans just PM me.
Printed the scans and used them to trace over the lexan with the protective films still on, then scored with utility knife and split the lexan into rectangles.
Using my dremel too and the cutting disc on low RPMs - cut the corners and the long sides.
Switched to the scroll bit to do the inside curve of the lower plastic, then switched to the barrel sander bit to do the edge shaping all the way around. Wore safety goggles but I am hoping lexan dust won't give me lung cancer. Next time - dust mask.
The lower plastic I left clear although it should be translucent red. The upper plastic - my friend Ken (who is a graphic artist and web designer) vectorized, then printed on glossy paper (not sure what kind), then cut out the clear areas and stuck it to the bottom of the top plastic with packing tape.
I then just used a drill bit on low to drill all the holes and fit it all together.
Perfect? No.
1000x better than no plastics/broken plastics? YES.
These may be Stage 1. For Stage 2, I wonder if we can print the top graphics reversed onto a transparent sheet of adhesive backed plastic? That would look very close to perfect I think.
Same thing for the bottom horseshoe - just needs to be translucent red, stuck on and the edges trimmed with an exacto.
RussM