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I would just cut a piece of aluminum... shoot it black... then thread it to the top of the frame the flat area there, then you can use some wing nuts to get it on and off real fast if you need to... lay a piece of paper down over the hole, trace it... trace that to cardboard... then use that as a template for the alum. alum is the best bet as you can cut it real easy... it will bend a bit to mold and it is CHEAP in sheet sizes that small. hell after you cut it you can even run weather stripping around the edges (like you would find at a auto store) this would protect your paint and even do a bit to keep out the water...
Does it have to be a solid cover, why not use Polyurethane foam, you can bye a aerosol can of and just spray, it will fill the hole and seal it, it can be removed easily, we use it all the time to seal cable entries into buildings, you could sand it to any shape you want, even paint it black after, great stuff,
This is something I muddled over for a long time when I was considering a spring-seat for my Bob....guess I should've posted a thread about it.
Really though, the best I could think of was leather....some guys have done it on their Cross Bones since HD just used a plastic cover...I read that the MC took that route because they said a metal cover would've interfered with the anti-theft kit under the seat, but they did leather on the tank...no reason theycouldn't do it under the seat.
Lucky that is a great idea!!!! Bosken all you ahve to do is lay down some painters tape, then a bunch few layers of foil down just lay one one direction the other the other way... from there just lay down your fiberglass (wear rubber gloves and COVER THE REST OF THE BIKE... fiberglass is some mean stuff and will scratch just like sand paper to the paint if you get the dust on there and rub it) again lay this down in a chris cross pattern... then just let it dry... once is hard, cut off the excess so you have your shape.. then just sand the hell out of it, bondo it, sand some more.. prime and paint.. will look great! I have make about 5 of this style seat for cafe projects for the cafe seats and can give you links on how to make those if it will help... fiberglass is easy to do but is a pain to work with... after you fiddle wiht it a bit you will get it perfect... again... COVER ANYTHIGN YOU DO NOT WANT FIBERGLASS ON!!!!! not jsut the liquid stuff but also the cloth...
it is cheap... you will only need fiberglass, a paint brush, fibrglass cloth, foil, painters tape, bit of bondo... and time... woudl look the best. Great idea Lucky!
if you go to the hardware store for the stuff i bet you can do this for under 20 bucks
and if you really need... once things are all done at the house i can make it for you on my bike... it will be about a month before i can start it but i can mold it up and mail it out... would take me just a few nights.
(when you do your mold, remove the 4 bolts that hold your battery case and fuse box this will allow you to mold into there as well and then drill that out so you can run your bolts though it, you may want to even stick some washers in the fiberglass as it is drying so that when you torque down those bolts it does not just crack... i would drape drop cloths on both sides tank and rear fender... fiberglass resin can get sloppy.)
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