TheOrangeTier: never thought of starting with an earlier surround and cut/fab to add inside lower lip and my first thought would be that the profile on top seems less sloped on Mk2 than Mk1 style grill surround (but don't know, will put a profile/contour gauge on both types and get back to you. Also agree CNC may not be an option due to wing close to orig. thickness - when I fit a Mk2 surround in a car I can better visualise clearance, but if CNC might be an option it would need to be 'thicker' to hold up to the machining. Bar stock is pretty pricy these days so materials cost may be an eye opener as well. My thinking is the most resonable cost option would be if we could find someone, somehow to do stamp or roll brass like original (> Austin Healer : agree brass would be easier if stamped or rolled)