I work for a company in Wisconsin, and we are currently buying ABS vacuum molded bumpers for our product (26"x6"x3").
The issue we face now is that we are needing a Z-shaped bracket to be mounted to the same surface as the bumper, but the bottom mounting base for the Z-shaped bracket needs to be placed under the bumper's edge. Our first thought was to notch the hollow bumper to make room for the bracket. The problem with that is it would produce a hole in our sealed hollow cavity, and allow water to fill the space.
My question to you is: Would it be possible to use a heated block coated in Teflon and mounted to a horizontal surface in which we could press the ABS plastic bumper into to produce our recess without the hole? The recess would need to be 0.25" in depth, 1" wide, 3" tall, and centered on the 6" length. We were thinking the block design would need to be ramped up to the 0.25" depth in order to not puncture the cavity, and if it made a small hole then we could patch it.
If this is possible... Where could we go to get the equipment (block, heater, etc.)?