That looks great. What did you use to cut it?

 

wow, that does look good. how did you get the edges smooth?

 

ya like the edges wont rust...

 

I have been thinking about doing this... but was afraid to attempt it... was just planning on using my dremel... details would be appreciated.... looks great

 

I covered the aluminum insert with duct tape, then I cut out the center section with a die grinder with a 3" fiber cut off wheel, I put a tight fitting bolt thru the center hole and secured it with a nut, then put it in a drill press on slow speed and used the die grinder to trim the outer edge, then I trimmed the back side edge so you can only see the trimmed edge on the back side of the cover. If your worried about rust, you can paint the back side edge silver. Also the center hole is not exactly centered so you might want to use a loose fitting bolt and center it before you start.

 

The best trick for this is to put some clear finger nail polish on the raw edges, wont rust, drys clear and shinny!

 

Wow that came out very nice. I'm not quite sure if my bolts that are behind the cover are chromed though. It looks great!

 

Damn, that looks really good!

 

If you drilled a hole first, could you use a band saw to cut the cover?