I'm quite prepared to be the guinea pig and will supply my bumper to Argon for moulding purposes. Having spoken to them today, their response is as this:
We did have plans to fabricate a performance composite part, however the client who had requested us to fabricate the part sold his RS4 and got a new RS3, so we lost the opportunity to get access to the car to replicate it to suit.
To manufacture the parts we would need access to a front bumper, preferably off the car but it could be done if the bumper was still attached to the car given a day or twos access to it.
We would also ideally have an existing front splitter that fits the car, like the seat one, condition not too important although being in one piece would be good. We would remodel the two ends to suit the curves of the RS4 more accurately, then mould the whole modified splitter and produce new carbon fibre front splitters out of the moulds (simples as a popular meerkat would say).
Cost wise - to sculpt ,mould and produce the front splitter it would cost around Inc. VAT:
Sculpting moulding and refinishing =£280
Production parts in standard 2x2 twill or plain weave = £300
You could also have an input on the design and shape of it, though it could affect the above costs if it became too extreme. We also have in the past done bulk buy discounts or absorbing tooling costs, so if you have multiple people interested in buying one we can come to a deal.
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I don't know the correct way to proceed but I'm sure Argon would appreciate some comments/input/orders before they kick things off. Please post your comments and I'll take it from there.