Air Dam
Jason,
A friend of Mine and I have contemplated this also. I started a design using 3-D solid works software. Getting the design that everyone would desire would be the difficult part in my opinion, and me finding the time to finish the design has been a little challenging.
My friend thought it should be similar in appearance to the hot air cars, maybe a little taller. He also thought it should have the same finish as the OEM piece so it would not require painting. My opinion was, it should be smooth with an opening off to one side that would let air flow into an aftermarket air filter system. It should also look a little more exotic than the OEM piece, and require painting. It could be done either way, however if no painting is to be obtained the part must be made so that it is UV resistant and wont fade when exposed to the suns rays, which would increase the cost of the part.
I am an engineer professionally and currently have a long list of many plastic components that I have designed. My first engineering job out of school was for an automotive conversion company called Centurion Vehicles. While employed with Centurion Vehicles I designed many plastic wheel flares and front air dams for the trucks they manufactured.
This is a perfect opportunity in my opinion for vac forming, however the tooling cost may be rather expensive. I have three plastic vendors that I deal with regularly at my place of employment currently. I have developed a really good relationship with one of them, and have tossed the idea around in my head about having them quote me a tool for my rough design (just so I could make a better decision on whether to pursue this or not). I wonder what the cost of this air dam would have to be in order for it to become a popular piece?