I live in Raleigh and ended up ordering on line last year from here: http://www.diyroadcasesstore.com/ plus, flames!

You could call sign companies or plastics companies and try. I talked twice with a plastic company, I believe, in Greensboro. They had the ABS I wanted and took my information and were going to call back with the final quote and let me know when it would be in stock. After calling them back twice with no record of past phone calls over the course of a month i was fed up and ordered from the above website. i screwed up a couple of times so it was good i had extra plastic.

the whole point story about sourcing plastic is that, it seems two 27" discs of thin plastic are not high on the priority list of a company dealing with large scale production jobs. when i explained over the phone what i was trying to do you could almost hear the eye-roll on the other end of the line.

this is probably the sheet you are looking for:

http://www.diyroadcasesstore.com/abs-plastic-sheet-black/

THANKS!!!

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I just made a disc cover a few weeks ago and used High Impact Polystyrene (HIPS) that I ordered on Amazon. It's white, and I've heard it degrades a little when exposed to UV, but I used carbon fiber vinyl car wrap (because I'm a poser) to protect it. Adds a little bit of weight, but not much.

I cut the squares into circles myself. It wasn't an overly difficult process, it just took a little patience and a sharp razor blade.

HIPS: http://www.amazon.com/...00?ie=UTF8&psc=1
Carbon Fiber wrap: http://www.amazon.com/...00?ie=UTF8&psc=1

When I cut my circles, i used a push-pin to pin-down the radius point. i pinned it into a piece of lumber. then, i tied a length of rope under the push-pin and then tied a pencil to the other end such that the pencil marked the radius of my rim. then, holding the pencil vertical and steady, i was able to turn the plastic, like a record and get a reasonably perfect circle.

and a sharp blade helps the cutting process. the trick is to go over the cut 2-3 times with the knife instead of cutting it all in the first go. i recommend this knife if you have to buy new. you can pop off the dull edges, and the handle lets you push with your thumb unlike a regular xacto handle. i used this blade for 10+ years building architectural models.

im pretty slow, so this is really the only area of expertise i can contribute to this forum.