I know I've seen others do similar mods to their pully covers, I think it was Doody814's bike that made me think of doing this.  So I purchased some grill mesh off EBAY for just over $20 with shipping, it's 6"X36" as I plan on doing something similar to the belt guard too and needed the length.  Just a quick run through of what I did.

1-Basically just made a paper template of the inner area that could easily be cut without going too deep into the thicker reinforced areas then just used a sharpie to mark the front.

2-Grabbed the angle cutter and took out the straight lines.

3-Used the Dremmel on the corners, grind some of the reinforced areas and to smooth out the rough areas.

4-Used a file to smooth the edges and put a scratch on the face too!  LOL (skip the scratch if you plan on doing this yourself)

5-Cut the grill mesh with some hand snips and trimmed to fit nicely.

6-Drilled and riveted the mesh in place.

Took less then an hour and other then the scratch and over cut corner I custom applied it looks real pretty  




EBAY link for the mesh I purchased-  http://www.ebay.com/itm/190630630977?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m...


Sorry there's no pic of it on the bike, I'm kinda in the middle of tearing things apart and messing with the bike HAHAHAHAHAHA

Nobody much here on weekends, Toes...
I post a lot of zero responses too...

It looks pretty good... It'll get seen a lot more in the next couple of days...

So lonely here on weekends... ...

...

ToesNose wrote on 09/22/13 at 18:00:32:

I know they don't... Two or three of those post counts was me as Moderator, just looking in to see who's here (We Mod's can see that),... if I'd been worried about yer' soft shell, I'd have posted then...
I do do that for some noobs occasionally, just to help them feel encouraged and welcome...
(Note you guys.. be nice to noobs)... ...

You got over 1,000 posts,Toes... I don't do nice, nice for ol' farts like you...
...

Nice concept, Ill betya puckered when the cut-off walked past the corner,

@JOG- I didn't even realize till after, but there was definitely a sad face involved  

@Serow-The cover is a chrome kitchen drawer pull I sanded to look like brushed aluminum, as for the armadillo let me know if you really are going to do it I'll mail you mine as well!!  

Toesnose:

That looks great.

Now......you can do the rear brake to match!

ToesNose wrote on 09/23/13 at 04:37:06:




Pain teaches.. IF its possible, working on the inside hides little boo boos. If its not possible to cut inside, clamping real steel stops at the end of lines will help ya out. Also, since ya wanna radius in corners & ya wanna see them be the same, starting out by setting up with a compass & dividers & whatever it takes to find center of a hole that would land IN each corner, then drilling holes for corners & connecting with a cut off will
NUmberA Protect your part from Over Run at a corner
& 2 Hook you up with a nicely radiused  opening.

If the divot bugs you you  mite try stirring up some JB weld & mixingit with some aluminum powder made by filing a bit ,,Just hafta do a trial run, see how it looks. Nick the edge of something & fill it, like Bondo, Orrrr,, call it done,I would,

@Dave- I love the look of that rear drum! I was originally going to do an border/molding of metal around the edges on the outside like the drum mesh has and may still in the future, but the mesh I got was thin enough to just mount from behind wich is good enough for now  

@JOG- it doesn't bother me, on the bike you barely even notice it unless you bend down and look close.

@BabyHog- there are raised reinforced areas on the back and I didn't want to cut too much into them so that's why that side ended up where it is