Getting the hanging panels vacuum formed out of the same plastic as your garden chair.
There are some advantages to this material, namely:
- Weight, the standard bonnet is just under 20kg, the plastic one should be around 2-3kg, the boot lid will see a similar reduction in weight. The guards will see a little weight saving.
- Serviceability, if contact is made, rather than shatter or break like 'glass or carbon, the plastic will deform and pop back into shape on its own or with a little help, but doesn't need panel beating like metal panels. If the hit is big enough, then the panel will split. However repairs can be made by gluing back together with acetone, basically a bottle of nail polish remover on the split. The plastic will be at 80% strength or so after about 10 minutes. Also the plastic is white, so no need to paint them, just get the shell painted to a close match in white.
- Cost, after the setup costs of getting the molds made it will cost me a couple of hundred dollars in materials to get a set made. It has cost a bit to get to that stage, so to recover costs, I am looking at selling them for the drift and flat brim crowd. If myself and the manufacturer can keep the costs to similar to 'glass there should be a market. The biggest costs is getting the molds set up.
Also making modifications to the panels is pretty easy, by cutting or gluing for flares on guards and venting the bonnet if needed.
So a little method in the madness of taking advantage of the freedoms in the 2B rules.