Thanks for the info Darbikrash - I'll have a look into the soldering. At the moment I'm looking at the scanning/CNC-machining option as it might work out quickest and easiest.
In other news I took my Pontiac's seats and door cards up to the trimmer (Steve at Trim Lab in the NSW Hunter Valley for any Aussies reading) as he will be recovering them in a new simpler style.
My front seat needs a fair bit of love.
I had a pretty decent fail, too. I unwrapped my new reproduction kick panels, which I had bought ages ago as I knew my old stock aqua ones were pretty beat up. These new parts were advertised as a direct fit, direct replacement part.
I've also gone through the list of what's needed and ordered new:
- window regulators
- door latches
- window felts
- window channel rails
- quarter window frames
- sealt belts & retractors
- window felt kit
- arm rest bases & pads
- door fastener kit
- front-end panel alignment kit
- all hanging panel bolts/fasteners
- moulding fastener kit
- rubber bumper kit (bonnet, boot, fuel door, doors)
- fuel tank mounting kit (including rubber strips)
- rear-vision mirror
- rear wheel cylinders
- rear wheel bearings & seals
- diff pumpkin gasket
On the engine side of things I've made some basic brackets to hold my fuel rails out of 3mm aluminium. The rails and brackets are getting powdercoated now and I'll fit the intake manifold, throttle bodies and fuel system as soon as they're done.
As always, more pics and info
HERE