Ouch. Sorry to hear about what you are going through.
I know you said the passenger rail needs to be replaced, what about the rest of the body?? What is your timeline to get it fixed?
Maybe you could fab up a boat tail and create a really aero design, then have it painted up to look like it was factory??
On second thought, can you part it out and get a better car for FE? The HHR is good for 30 city (EPA), so maybe it isn't worth fixing?? You'll dump $6,000 into the body, right? For $6,000, you can get a decent car that can probably get 40 hwy without changing anything. Just a thought...
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