Actually, I think you did a great job describing the problem, communicating your problems with the manufacturer and coming up with options for a fix. I think your plan number three is the best one. It does the job, will probably last longer than the original plastic and by painting it satisfied the cosmetics. The only question which will get answered over time is: will the fix really last longer or be affected by the slide extension and retraction.
btw - I really like your model of monty... a lot.. :-)
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