[rsk289]

I would very strongly recommend you buy a Ford Prefect (100E) heater unit to use as a core. They crop up on ebay and are not expensive - mine cost me £5.00. Making the casing shape from scratch would be very difficult as they are a pressing, with the tapered section and the ribs part of that pressing. Also you will never replicate the Delaney-Gallay pressing which is very complicated.
However if you tell me which measurements you would like I can certainly take some while it's out of the car - but as soon as I get the modified matrix back from the radiator shop, it's going back in!

Roger