The initial attempt to make a new threaded insert for the truss rod didn't really work. I heated the end of the steel bar up to "cherry red" and then formed a mushroom shaped head on it by hitting with a hammer, but it wasn't really working well and the shape of the rod was deforming too much.
So I changed tack and tapped a thread onto the end instead; then put a self-locking nut on and peened the end of the rod over the nut (so it couldn't come off).
I'm pleased with the end result - it should work fine.
The next stage was to cut the bar to length and then tap a thread onto the other end to take the adjustment nut. Then reinstall the threaded rod into the truss rod channel.
I'd managed to find the washer from the rod rattling around inside the guitar, so reassembled using the new bullet adjuster nut that had arrived.
This shows how the rod is adjusted with an allen key. Just adding half a turn of tension produces quite a bend in the rod, though I'm sure it will be less pronounced when restrained in the neck..
And this shows how adjustment will work once the fingerboard is re-glued.
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