Hey Dave,
You probably should contact some prototype makers of vacuum formed plastic parts locally to check the possibility of making the plastic part you intend to install on your kayak. The vacuum formed plastic part can be sprayed into the color that matches your kayak easily. You should check with the vacuum formers who are focused on making plastic parts out of thick plastic sheets.
Hope my input helps!
Joe Zhang
Project Manager
Ekko-Pal Industries Limited (Dongguan)
Room 1503, D Building, Kaiyuege, Kaidongxincheng, Dalingshan Town, Dongguan, China.
Tel. +86 (0) 769 8187 0779 Mobile. +86 (0) 135 1095 1485
sales@ekko-pal.com www.ekko-pal.com