Coating acetate or other plastics is a whole different ballgame than glass. It's far more complex.
Also, glass is pretty cheap. I always used plain float glass for photo purposes. Cut to size at home, burr edges and enjoy.
They're the same film. Get whichever one is cheaper.
Also, I don't think 4x5 is particularly expensive if you shoot Fomapan. You generally don't go out and shoot 36 frames of 4x5 on an afternoon. Since you generally shoot less in the same timeframe, the costs don't add up too much.
Also, I still think you're massively underestimating the complexity of manufacturing your own plates. Sure, it's possible, but it's a long and steep learning curve, and even if/when you've got it under your belt, you'll be spending a lot of time making materials that you could otherwise spend making images. It might be a good idea to reflect a bit where your heart lies - in making images, or spending time in the darkroom playing around with materials.