Probably not so off the wall with the exception that I am incredibly anti social, and just have never been able to cross the No Facebook barrier I imposed upon myself. Man that sounds silly.....

Have reached out to Zagato owners groups and discussion groups, but hardcore Zagato guys really are, um, embarrassed by the existence of the Zele. It is just so far removed from the vehicles they associate Zagato with, like Zagato got drunk and whipped out this silly little car before they knew what they were doing...lol. 

Jayhawk: Will look into Dino Spider hinges, thanks for that suggestion. I'm getting used to dubious searches!

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F253332333023 

Fiat Dino Spiders have very similar trunk hinges.  Mine is in storage, so can't measure.  Also, since only about 1500 of those were made, the availability of spare hinges is probably dubious!  Good luck.

An off-the-wall suggestion--have you tried Facebook groups for this marque?  They exist.

Kidding you not, I have seen very similar used! If I can find the picture I'll post it.

I'll bet you could make these work. Just kidding. 

That's a good thing.  You can always cut down larger hinges to the size you need and tap new holes in them as needed.  That will cost less than making anything from scratch.

I too have noticed the different hinges in pictures but every Zele I've seen stateside has the Fiat based long thin hinges. Perhaps the Euro models had the smaller square hinges, not sure. Regardless the body and door mounts are different for the square hinges.

Finding anything similar the approximate length has proven difficult. The closest I've found are about an inch longer which would extend the hinge past the raised mount area molded into the Zele body. I know it's nit picking, but urgency is not paramount so the search continues.

Thank you for the thoughts and ideas!

The pictures of different Zeles online look like the door hinges are a bunch of different types. Why not find some available ones that are the right approximate length and style and just modify the mounting holes on the body to fit? 

No you can't.

You can aluminum weld it for sure., that’s a piece of hisrory you dont  want to just replace them with new and shiny chinese made hinges.

Cool, I have a '93 Trailbreaker we use it for bicycle race set up and towing a snow groomer.

Currently own two, a Trailbreaker and a RT340

I'd suggest bronze if you have them cast lots of small art foundrys do bronze.

Is your screen name because you own a Rokon?

Many thanks for all the suggestions and opinions, I think my next move is to head to machine shop and see what they offer as far as ethe casting or CNC goes.

Love the "corner the market" idea...funny!

While CNC machining the part using surface geometry is a possibility, you need a CAD model to start with as Onetim said..  You won't be paying for just the CNC work, you will also be paying for the scanning and model creation. 

If you have a set of semi functional hinges (yours or borrowed) the sand casting idea may be your most economical choice.

Not sure how much casting costs, but a decent machine shop could CNC the part in any material 6061 Al, 4140 alloy steel that would be a lot stronger, and you could make some spares for others to cover or reduce your costs. Make sure you get a copy of the CAD data for future copy’s. You could corner the market!

if they are pot metal isn't that non weldable and non reprairable?

If so, then having a set sand cast out of brass (or bronze or aluminum) may be the only answer - this issue comes up with a lot of old cars with no parts reproduction supply sources, the material used originally wasn't very good and the only way is to make new ones.


N

Might be an option if I myself had any broken hinges. My car has two unbroken hinges and the pictures I've been using of broken ones were sent to me by a fellow Zele owner who has no desire to part with ANY of his Zele parts.

Thanks for the suggestion

They certainly do but it appears that reproductions are unavailable () and finding a set of used or NOS extremely unlikely.

I do very much appreciate the help, many thanks!