Yes, I checked into polypropelene plastic moulding. For mass quantities it could be the way to go. Not for 10's or even 100's. 20k at a minimum for the intial tooling and then you would have to buy mass quantities of polypro to make per unit costs low enough. You would have to expect to sell 10s of thousands at least to make it cost effective and you would have to have thirty thousand at least to invest in it up front and then they would have to be more expensive than what I am offering now. That's why Bushwhacker doesn't go after it. They know that they can't do it and have it be profitable.I don't know how much it would cost but have you thought of doing maybe injection molding with a durable rubber/plastic mix? To be honest I wouldn't even know where to start but I just have a feeling that a more pliable, rubbery flare that could be easily reattached would sell very well. If I recall you're making these out of fiberglass? I've worked with it before and it's a PITA so I don't blame you for the high price. I'm sure supplies aren't cheap and they take a lot of work to make. The do look nice though.
We are using a very high quality fiberglass that is very durable especially when attached from the outside and I'm able to keep the cost at a level that should be reasonable. It isn't possible to make these out of any material and sell them as cheaply as Bushwhacker flares. Sorry. As I said before, I may only be able to make a few and then quit making them. I will keep the moulds in case someone that has bought them needs a flare section replaced, but I won't keep making sets if people are only willing to pay $500 or less for a set. I can't.
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