Just a follow-up on the earlier thread:
I indeed found a replacement dial, repro, seems like the last one on planet Earth. This radio (which was filthy from end to end) is now finished and ready to ship out.
As it turns out I still don't have a good means of making these, but I've learned a lot and received some good ideas. One thing about the internet, and sophisticated home printers, a lot of this type of thing has become available where it would have been impossible just a few years ago. I personally don't want to get into the dial-making business, but I've got more resources than before, and next time the procurement process will be easier.
Thanks again everyone for all your ideas.