Looked at the epoxy and reflector method; not enough space for the D2S 3.0 projector and I have no interest in going back to the generic projector.
So here's mounting plate 2.0 so far. I should be able to mill most of this and touch up with the dremel. Or just dremel the whole thing with a paper overlay traced on it. I have measurements this time instead of just winging it. Going to use 3/16" ABS sheet instead of 1/4". Also going to get some stock chromoly or stainless or something off McMaster and make my own mounting brackets for the threaded pivoting aiming nut things. No more of this ghetto-brackets-stolen-from-the-newgen-stuff.
I also looked more into the vacuum forming method. Up till now, I've been banking on 1/8" Lexan. After some science, it's not right. I'm going to look into thinner polycarbonate (maybe 3/32" or 1/16"?) and buy a 12x18 vacuum table instead of getting a short throw shifter for my car. Priorities.