after chatting with wurzel today, a carbon/rubber one could work an look great in a modded car, but if your going for original- take ivan up on his offer. he might chuck in the other leg for free!

We ues a product at work which we make foot orthotics from which can be heated and moulded which is soft.
If you PM me the size and your address I will send you some.
We also have a rigid material which is used to mould sockets for artificial legs if you decide to have a go at a rigid one.

Was having a look at mine again today and I'm wondering how much of the boot needs to be rubber?
It seems that the main purpose of these boots is to serve as a control arm protector, element guard and aesthetics, now I could be off the mark but I'm not convinced they need to be rubber for any kind of movement accommodation of the control arm.
If so then, what about fiberglass, carbon fibre or some kind of easier to obtain rigid structure?

If there is some kind of rubber element needed, then why not make a rigid frame and just attach a rubber flap across the face of it?

I just wound my jig down a little further and split the 3mm neoprene,

I will update this thered with my success of failures as they happen.

I had a look at a video of a guy pouring some moulding rubber.
To do it properly it requires a vaccum chamber to revove any air from the moulding rubber.

I have done a little injection moulding at work as we used to make some of our own parts.
China is cheaper so they have sold most of the machines now.

haha certainly a bit of a mission, i didn't even realise there were covers for the suspension arms

have you watched any you tube videos?

My first try was 1.5mm neoprene. it worked well at first but has now relaxed.
I curently have 3mm neoprene in my jig.

I have just sent off an email to a company that manufactures unvulcanised rubber sheets in brisbane, Hopefully they reply to me.

If I make a mould I will heat and stretch some acrylic and use it to cast both sides of a mould. maybe have some polyurethane poured into it.
I never thought I would be getting this deep to make a bit of rubber. wow.

from my experience stretching rubber doesn't work real well, i'd try make a plaster mould of the original, stick some rubber over the mould and then use an oven to heat it up. i've used that method with plastics and what not but haven't done it with rubber so may or may not work but i'd try it

edit - how thick is the rubber your using?

Thank you, very much. I think you may have hit the nail on the head.
It looks like I need to find unvulcanised rubber.
I think that puts me one step closer to success.

What about tyre retreading rubber?

It is uncured to start, they mould the tyre and then heat cure it in a steam oven.

Maybe your local tyre retreader could help out with supplies, advice etc.?