I think you are right about the figures.
I also think it's going to be difficult finding a company which will make smaller quantities of a product which they in essence will have to custom-build from scratch.
The initial outlay (development, new tools etc.) has to be rewarded by a big production order otherwise it may turn out to be prohibitively expensive.
Don't be discouraged - leave no stone unturned etc. - but it might turn out be easier trying to source an existing item which fits the bill. Or even building somethign from scratch yourself? You're good with your hands and very creative, Jess, I bet you could build something out of scraps of ABS, or even make a mould and form parts.
What about talking to Steve (TANGO'D FETT: http://forum.whitearmor.net/index.php?showuser=1939) about developing some resin parts. He's even casting the ESB greeblies in a rubbery material now.