I'm trying to make a panel that will replace this crappy diamond plate (as seen in the photo below). I would like to make something that is flush with the dash, this has been troubling me for some time. I thought be best option would be to CAD a part and then have it machined or printed, but that would be difficult given the 3D curvature of the dash, as well as costly.
I thought laying fiberglass would be a pretty easy way to make a rigid part that matched the curves. And from there I thought it would be fun to use Kevlar (I'm a Kevlar fanboy from using Kevlar rope in a lot of climbing gear).
What would I have to do to make a Kevlar panel that matched the curvature of the dash? Is it as simple as laying a layer to match the curve, and then building on it from there? Or would I have to use some sort of vacuum to get the layers to set properly? Would it be easier to use fiberglass?
I'm a college student, so my resources are limited to a (very nice) collection of hand tools.