I just wanted to say great work on all of the research you've put into this- I imagine many of us will need heater cores at some point, so hopefully, a suitable replacement can be found...otherwise, we may just have to get a radiator shop to make a custom one and record the exact specifications for future use.
Of course, heater core failures are most definitely not common just on our cars, but it does kind of concern me the amount of corrosion we tend to have in our cooling systems. The under-floor coolant pipes, for example, should NOT rust from the inside out if the coolant and its corrosion inhibitors are working as they should. What coolant are you all using? Personally, I am currently using BMW Blue (G48), as that's what I use in everything I own and is readily available. Liqui Moly seems to have some great options for coolant as well and coupled with regular change intervals hopefully corrosion can be slowed to a rate that it's insignificant. We have quite the list of metals in our cooling systems, so compatibility definitely needs to be verified with each and every one.
I was originally using a Zerex G05, but it kept turning "rusty" as quickly as a few weeks of use- even after numerous cooling system flushes. Since switching to G48, this has stopped, and it has remained relatively clear in the 6 or so months it's been in the system. The way I see it is if corrosion is the killer, then a bit of extra inconvenience or money spent on getting a premium coolant could definitely save the hassle of heater core and coolant pipe failures in the future.
Please excuse me if this post is off-topic for this thread.