If you had a custom replacement made, you would be messing with the panel's UL listing by installing non-factory parts. If any metal has been heated to the point that it has been discolored, it can't be trusted anymore, electrically or physically. It must be replaced.
There are lots of companies selling used breakers and panels on the Internet; I would go there via Google to get started. The liability associated with this is way too high to risk replacement with custom-made replacement parts.
By the way, I don't know what brand the panel is that you mentioned, but there is an Eaton (Cutler-Hammer and Westinghouse) facility in Sumter, SC that handles obsolete/out of production products for these brands.
[This message has been edited by EV607797 (edited 12-20-2006).]
"But the guy at Home Depot said it would work."