NetDoc,
For caps there a quite a few ways to engineer the caps.
Take a look at the openRov project, create a mold and use smooth-on plastic or ask... There a several dive light builders on Scubaboard and candlepowerforums.com with the tools to assist.
Personally I use delrin rod and cut it down with my mini lathe. I can cut 3 inch material, and am modding my lathe this weekend so it can handle 4inch. All I'd need is a sample of the pvc you're using to ensure a solid fit.
As to the maker movement, I'm working on a dive computer, with pp02 and other items... Clear pvc ( cast) makes a fine in expensive housing.
adafruit was mmentioned also try sparkfun.com, pololu.com for sensors and ideas.
for circuit designs and builds a combination of upverter.com and oshpark.com has been working well me.
Cheers,
Chuck