As mentioned in another post, the timing belt idler pulley melted, delaminated the timing belt and introduced the pistons to the valves in my Mum's 2008 Holden Astra.  I've recently found out that Holden only imported 2000 of these from Europe, where they are made and sold under GM's other brands Opel and Vauxhall.

All of the cylinder repair places here told me the same story - no parts available and nothing they can do.  Doubleboost helped me find a couple of options in the UK and I've just placed an order for a fully rebuilt head, head bolts, head gasket, water pump, camshaft pulley, camshaft position sensor, timing belt kit and other necessary gaskets. One other thing that I need is the drive adapter that enables the vacuum pump for the brakes to be driven off the camshaft, as this one gave up when all hell broke loose.  Unfortunately, you cannot buy them separately and have to buy the vacuum pump (another $90).

It is very simple and the tolerances are so low (i.e. this thing is a sloppy fit) that I could make it with the lathe, a hack saw, drill and a file.  If I pull my finger out tomorrow, I may have the mill operational next week.  Or at least operational enough to make this part.  I've drawn it up but for some reason Draftsight is not giving me the usual control on how the dimensions are displaying.  I'd welcome feedback on the drawing if anyone spots something I have missed.  I'm unsure how to dimension the chamfers but these serve no purpose that I can see.  The radiused groves are there to relieve stress as far as I can tell.  Sorry for the crappy pictures.  I didn't realize they turned out so bad.

   
   
   

I don't see any need for the detail on the bottom of the part either. It sits on a perfectly flat surface. 

Here is my drawing - remember, I'm not Ed:
  Astra vacuum drive adaptor.pdf (Size: 113.23 KB / Downloads: 7)