It does look like an expensive fix. I know most here can get their hands on the Denix and vote for a fitting for that. I'm more of a mid experience prop maker, but could jump my level a bit to make one of these. I'm a huge maker and collector of the Solo blasters from each movie.
I'm sure it is probably discussed on another thread, are there any good pictures of the DL-44 in the promotional photos? Not GK, not this one, but something without the grill. The flash suppressor seems to be of thicker guage metal/alum as the end looks like a large circle in the production/promotional photos.
BTW, you guys are a great asset to the forum.