I think there is maybe 1 or 2 who have made there own bash plate.

The best stuff to make it from it aluminmum as its light and strong enough to resist a good few knocks here and there. As for thickness, depends on what you want, i would say 2mm + would be needed to make sure it just doesnt split or puncture if your going off roading.

The only problem with aluminmum is getting someone to weld it, as your average welder at home normally only does steel.

I know your a student (or is it just young?? cant remember) meaning your strapped for cash but you can spend alot of time faffing about to make it when a good �50+ could be spent waiting for a good second hand one. (I spent 2 weekends making my own rack for panniers, which i would have bought for �150 or so)

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Plough on