Quick note on the UHMWPE, you will need to drill small holes in the plate for at least one screw per side to retain it. Any size screw between #6 and #10-32 should be fine. UHMWPE is really slippery stuff, easy to shape with woodworking tools, and amazingly tough. Most plastics suppliers stock it. My guess is ½" thick material would be fine. It is a lot more work to make is an untested idea so I would test other alternatives first.
I agree with Eric, you might have too much bulk. Have you tried just using unmodified stiff 2" webbing?
I did observe that stiff webbing didnt make the shoulder to under-arm transition into the slots as smoothly on my female friends small Freedom Plate as my plate does on me. It was tolerable on her, but she is at or above average height. Please let me know how your experiment works because it might improve her harness as well. We will be making some pool dives with it next month to refine her whole system for both tropical and cold water.
We tried my friends plate without rollers but it hurt her injured shoulder too much to pull slack or do the slip out trick.
We also tried soft webbing that was more or less fixed at the lower slots, but that didnt work with her shoulder either. We didnt proceed with the UHMWPE test because the soft webbing was so limp when wet it would be harder to don in a suit. The springiness of stiff webbing really does help getting in the straps.
Thinking aloud here:
This was my first serious effort to help a female put her rig together. Their body-mechanics vary a lot from males and between each other. Their arms really do move differently. The old joke about girls throwing baseballs funny is founded in anthropometrics. They can learn to throw a baseball just fine, but not using the same techniques as the average male. Thats probably the same reason mens shirts didnt evolve with back zippers. Compound all that with a shorter torso and an injured shoulders and suddenly my bag of tricks is almost empty.