Someone over on another forum made a mold out of the OEM key and a new plastic key head. Then they took the metal part of the key and put it in the mold and they used some very hard black resin to form a new key head that will not break. Very good idea IMO, im going to do it one day. Until then i'll just keep buying key heads for both my cars...

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1985 300TD Turbo Euro-wagon
1979 280CE 225,200 miles
1985 300D Turbo 264,000 miles
1976 240D 190,000 miles
1979 300TD 220,000

GONE but not forgotten
1976 300D 195,300 miles
1983 300D Turbo 175,000 miles

http://i42.photobucket.com/albums/e3...e485-1-2-1.jpg