Just a thought but why not take them to a 3D modeler ,cad cam prototyping shop , they can trace them into a computer model which can then be used to either cnc mill a mold from either wood or metal or there are places that could shoot a laser into a tub of surfboard resin and create a mold that way , there is even a way now to 3D print objects from a 3D printer that creates slices that are glued together to create the actual object {search the 3D paper gun project} . I think if you are on to something with the vacuum forming idea if we can just figure a cost effective way to generate the mold we will be able to use it to go either way with fiberglass or vacuum formed plastic .
