This was one of the projects that I was going to pursue for a while. But got caught up with work and had no time. Here's a few things to keep in mind, if you haven't thought about this yet:

1. You may want to check on is the material durability. I've seen printed parts using abs material and even though it's abs, the parts were not as strong as something injection-molded or thermo-formed. Inquire with your vendor whether the material they use will be durable against the elements and NOT brittle or susceptible to UV light.

2. Your parts, depending on the type of printer quality, may have step lines which will require post finish work (sanding) to make it smooth. The better/smoother the print results, the more cost it may incur.

3. I assume you will be having the part 3d scanned? If so, have them do a 'mirror' image of the part on CAD so you can get a right hand drive duplicate as well.

4. Lastly, since the mirror is convex and uniquely shaped within the cavity of the housing, you can have that part printed separately and have it chrome plated for a mirror effect. This may require you to remove the actual mirror from the housing to get scanned separately. Again, have them mirror this in CAD for the right hand version.

5. The metal bracket that gets installed inside the fender to attach the mirror, can be fabricated out of stamped metal of your choice.

Hope this helps as I would like to see this come to full fruition. Good luck and let me know if you have any questions. rudy