Hi Rudy...
I just ran across a vendor of mine that does the 3D printing in ABS.. first time I've come across that. Unfortunately they don't contract out their machine as it's fairly full with their own parts. They did mention that it was the cheaper option for them.. so hopefully the costs will be more inline.
I haven't come across any further information to help with the prototype costs.. but if you run into issues let me know and I'll see what I can dig up for you.
Still can't wait for these! I'd love it if the grills are EASILY removable so that I can pull them off when I was the car and get the bugs out. I tend to kill a lot of bugs when I drive apparently.. and the red of the dead bugs screws up the MEAN paint job!