We used to run polycarb and PET in totally clear for a company that made medical implants, The flashing was removed by hand and you could hardly tell how it was run: no tool marks. I've never vacuformed, or blow-molded with plastic so thick before, but we've done standard injecton molding with a little 50 ton with glass like results.
I would assume that Buell/HD could afford some bomb ass tooling.
+1 Lando on the PolyCarb....you're probably right.