Hi All,
Thanks to all the above posters for your posts.
I have, today, fixed the front left hand side window regulator (the Boss 's window).
The disintegrated roller was the rear most on the bottom channel. The rollers on the front most and the top channel were good.
I used the 'make a block from a cutting board' method, (I now owe the Boss a new cutting board as she, for some reason, doesn't want the old one back). However I don't have access to a router so all fabrication was by hand using hacksaw, coarse file, sandpaper and drills, and elbow grease.
I also used Dolphinberserk's method to clip it onto the original mounting post on the arm, as it was solid but I had to reform the end of the arm as it had distorted.
I did not use the 6mm cutting board but a 10mm thick one because it was available and it can be made to be snug on the mounting post of the arm and the full length of the mounting post bears on the new 'runner'. It finished up as 25 mm high by 40 mm long and about 8 mm thick and used the original wavey spring washer.
The recess in the face for the mounting post head was done with a suitable drill bit (12mm) twisted by hand to get just a shallow recess and not go too deep, THEN the through hole for the mounting post, of 8mm, was drilled. This left a neat slightly chamfered recess which worked just fine.
One thing I found which is not mentioned in previous posts.
My metal channel that the rollers (and now the new runner) travels in was a little worn from the action of the mounting post rubbing on the edge of the section and creating a burr. I carefully filed off this sharp burr so it would not cut into the new runner and chew it out prematurely.
I fitted it with a liberal dose of Molybdenum Disulphide grease to all parts of both channels and this freed up the other two rollers nicely as they were gummy.
All now works as good as new.
A second runner was made and put into the tool box ready for the right hand side should it be required.
This has saved me at least $75 to replace the whole regulator assembly AND I didn't have to remove the old one to fit the new runner.
Cheers GIL