If you are an accomplished welder/metal fabricator, have at it.
If not, you will soon find out why parts and peices are expensive.

One thing you can do is buy a "liner" which will contian the fan and then build the decorative enclosure.

Thanks for the responses.

Actually my DH was a welder and still has the equipment. He still welds things as needed. He is an advanced DIYer so I know he can do it. He wants to cover the hood in tile as he is not sure he could do a perfect job with stainless.

Just looking for info. Thought that there would be some DIY plans on the internet but haven't found any.

I will look for a liner but finding plans to build the hood (or enclosure) would be great. This is part of a huge remodeling project so this one item can't take too much money or time.