I have been working on a part for a yamaha motorcycle that basically replaces the passenger seat. (See attached) I am planning to have the upper and lower pieces thermoformed with 0.1in thick ABS plastic, bonded together, and a metal rod riveted to the mounting base (see the object that looks like a bar going across the bottom of the model)

So here are my questions: Is the mounting base (the more complex structure) doable with thermoforming, and is it advisable to use thermoforming instead of another manufacturing process for this? My budget for tooling is $5k and I would like to have the cost/part under $30/unit, is this reasonable?

I realize that the model needs some work like an applied thickness to the upper piece, but am I on the right track or am I better off going another route?

Thanks!