My long range diagnosis was indeed correct. That’s a weird thing to happen though - what glue did you use? It almost sounds like heat damage to me, rather than glue damage, especially the way the parts have curled apart.
As an expert kit burner in my youth, that’s the sort of effect you’d get it you brought a not-so-well-glued wing towards a flame… believe me - I know! [;)]
I know the stuff - I have a bottle of it with a little metal applicator tube. I’ve not used it much, and I don’t think I will again! Sounds way too scary to be waving about near my precious kits [;)]
How’s the repair to your vacformed bit coming along? Didn’t you say you picked the kit up in the bargain bin? Correct me if I’m talking out my a** here. If it was, it could have been the age of the plastic. Some plastics get brittle over time, so that might explain your catastrophe. If you take it nice & slow on the rest of the cut outs you should be ok [8D]
When you build the perfect model, quit! Otherwise, just keep at it and treat each model as a learning experience. Most vacuform kits are made from very soft plastic (PVC) and styreen cement will melt it quite easily. Try some other types of glue, like epoxy . Liquid glues that flash very quickly, like Tanex 7 or Weld-On #1, #2, or #3 can be used as long as you apply it sparingly. It should set up before it has a chance to melt the surrounding area.
Also, try sanding the vacuum formed piece on a flat surface of 220 or 360 grit wet/dry sandpaper (wet). Before yo do this it is best to do some scale measurements in order to determine if the thickness of the sheet of plastic should, or should not, be part of the piece. If the thickness of the sheet of plastic should not be part of the piece you can sand the piece until the plastic is paper thin, and then cut out the piece with a sharp Exacto blade. Vacuum formed kits are a real challenge.
Curing glues often build up heat-so it could be a solvent/heat problem. Next time you mix up a 2 part epoxy-hold the container just before the epoxy sets-it gets hot!