True, they do.
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Those preferably goes under shaft curve, just fine....as Minelab done at Advantage, Sovereign and others...Pretty nice and what is most important; pretty convinient. Prevent it to stuck somewhere in tight places. I do prospect mostly in woods,forests...a lot of trees,bushes,branches arround. That kind of handling showed as most convinient to me. Also original TGS box is simillar to this. Among other things it has enough volume to put all inside, including battery. Strujas pushed me to think to put Nokia cell phone batteries inside; 4x3.6v /3500mAH !!! They are small yet powerfull! I dont know where he founded them, but 3500mAH for sure is enough to supply TGS! Only thing must to do is to remove micro pcb with 78l05 smd regulator from each battery. All joined togather suits perfect in the box! These kind of boxes also let us to install nice speaker too. Instead those weak (from Chinnese toys) now i can install bettr one 0.5W/8ohms...Louder and better audio...To conclude with only 2 words; NICE BOXES!
Regards!
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Some quick thoughts as I am pressed for time:
1. Vacuum forming a housing is not going to work for a deep draw plus remember that the plastic is not a uniform thickness. I'd say the minimum thickness for a control box housing would be .125 ABS sheet and you will need a mother of a vacuum pump to draw that part down. 6cfm rotary vacuum pump * 2-3 pumps. The shop vac designs on the web can pull that paper thin polystyrene they use for model plan parts but not ABS. There are many other issues such as trimming the part, ABS is tough anti-cut plastic.
2. That 3D model you posted would need to be injection molded and as someone said the mold would cost a boat load of money. It also needs to be tapered.
I think you have two reasonable choices. Adapt a housing, Walmart sells a waterproof lexan box suitable for a detector housing for $10. Or take a look at some extrusion material either aluminum or plastic and machine the end caps. Just my two cents worth.
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