yep I'm going to get them vacuformed for 5 1/4 round speakers (also sotck flat ones) and out of 1/8 ABS so I don't have to repair the cardboard ones anymore. they'll be cut on the beveled area of the MDF you see for correct shape.
so far I've got the drivers side bondo'd up and fitted to the car and am working on the passengers side. once the molds are made I'll ship them to the vacuformer guy I know to run a test set to see where I screwed up (first time never is right) but I'm getting closer each part I try on. since it cost's 50 bucks each change I do I try to make it right ASAP.
since I have 2 darts to do I decided to just bite the bullet and make molds to get them made out of plastic instead of fiberglass. It helps that I can add insulation behind the panels also.