I am needing to remove a bit of chrome plated ( I believe is aluminum) material from my stock riser cover. As you can see in the pictures I need about 1/8" of material taken out to match my pattern. I'd rather not have to have it replated so I don't want to f it up.
I asked a machinist pal and he said to use a carbide burr. Anyone here know if that sounds right or have any other suggestions?

 

If the material is aluminum and its chrome plated the plating is not that thick. Chrome plating is only about .005 thick a most. If you have to remove 1/8" (.125) you should have it machined down to size and re-plated.

 

Is the problem the cover or is the problem the bar clamp?
Reason: The riser cover does not play well with standard "one" piece bar clamps used when individuals want to keep ape hangers from rotating. Most off the shelf one piece bar clamps (top piece) are too thick and make the chrome cover stand off.
If that is your problem the one piece top clamp is part number #55918-08. There is one on ebay with picture as it became standard about 2008.. Not a chrome part, not a pretty part but it is low profile since it goes under the chrome cover and keeps the install cleaner and there is no big visible holes on the side of the cover.

 

The problem seems to be the new 1-1/4" bars have a slightly narrower clamping area where the cover won't slip down in the 1" clamping area.

 

If the grind does not look perfect or if it remains sharp you could place some car door edge guard on it....kinda sorta like the factory puts on the nacelle part.

 

Only 1/8"? For best control use a hand file or the proper sized sanding drum or rotary stone. Rotary burring bits can be a handful at times and can get away from you, ruining the finish. Coat the edge afterwards, even if you do cover the edge with some kind of trim. Good luck!

 

Thanks for the input yall. I took the part with me yesterday and now I think it is cast steel. And the general consensus is that their is no way to grind it without running the finish because the whole piece is plated. It is looking like I will have to have it replated afterwords.