....Just wondering - been looking, but haven't seen any except the guy in China, I PM'd but no response.
Actually, I've considered this same solution... Just place CF louvers in a slotted plastic frame. This would still require both CF and plastic fabrication though and the overall market might be too small to make this feasible.Is there a cosmetic reason they need to stay as one?
The louvers wouldn't be hard to make if you can make each individually and attach them as a second stage. The differences in weave pattern wouldn't even matter, in context of the front, the weird angles would make it impossible to notice. The back square-ish ring around wouldn't even need to be carbon.
The only thing I can see being a problem is the heat from the engine and radiator. Even that is unlikely to be a problem, just something to check.
This all seems in the realm of weekend project rather than engineering nightmare. I think the hardest part would be getting louvers you're willing to break to make models.