I had the same D4 a bit ago.. if I remember correctly it had less than 2000kms on the clock.. it had a few more when I took it back though - 70kms each way to work will do that.. :)
It hasn't taken him long to make at all - he's busy and works away a lot so he's just done a bit in here and there when he's had the time.. and yes cheaper than a bought one. I just asked him what the cost of materials was and it came in at less than $500 including the materials for a steering guard and a fold down roof rack ladder he has also made, and laser cutting. Hours wise he say's less than 10, and it would have probably been less if he was able to spend longer blocks of time on it rather than a bit here and there.. Powder coating on top of that - should be less than $200 (going by what they recently charged us to power coat the roof racks).. :)
I couldn't wait to have it powder coated to see it fitted so we did a dry run this afternoon just to make sure that everything fits where and as it should before sending it off for powder coating... I think he's done a great job!..
https://www.aulro.com/afvb/images/im...13/04/1258.jpg
https://www.aulro.com/afvb/images/im...13/04/1259.jpg
https://www.aulro.com/afvb/images/im...13/04/1260.jpg

