While searching for vacuum-formed jewels that we could put LED lights into I ran across this resource today:
http://www.whatishcc.com/tutorials/
Its a site mostly geared towards costumes and some prop building, but they did have some resources for do-it-yourself vacuum forming, including a set-up that allows you to use your own oven! While I'm a bit hesitant to say this is entirely safe, It could be a nice trick for a one-off part for a show.
They also refer the used to a book put out by Tap plastics called Do-It-Yourself Vacuum Forming which you can order here:
http://www.tapplastics.com/shop/product.php?pid=20&PHPSESSID=20060531234852695724924
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