I used the great info from the forum and cut the football today, turned out pretty well. I found that for me using a handheld jigsaw with a metal blade worked better that the cutoff wheel, gave me more control. I did use the cutoff wheel to smoothe the edges though.

 

Nice job man! That mod always a major improvement in the looks department.

 

Thanks! Now the only question is what to do with the backing bracket. I think it's pot metal? I wonder if you can polish it? If not maybe powder coat. Not a bad job for the $3 I have in blades and $9 sticker.

 

Looks good man !!!

 

I'm stuck between a rock and a hard place as I like the stock cover for it's ability to keep the rain out.
I have the K+N high flow intake and filter with the same shape as the stock so I cannot use a smaller round cover.
I can't find another substitute.
here is the K+N intake and filter I have.

http://www.bikerparts-superstore.com...09-harley-dyna

 

Looks great! Of course I'm a little bias..


I did mine with a dremel cutoff & had a few close calls with it wanting to chew it's own path, looks like your jigsaw worked out pretty well. Over here the cost of powder would be more than just buying a new backing plate (unless you have loads of other items done at the same time). Rattlecan black might buy you a bit of time while you decide.

 

for the back plate we powder them all the time! no problem at all! hell i even powdered my Throttle body... we cut, and powder the foot ***** and the odd shaped air cleaner covers all the time! It is cast metal, so polishing would be insane amoutn of work with the grit sand paper changes and then polishing... would be alot of work! of course i would recommend powder

your cleaner came out really nice
here is what my backing plate, tb, and cover looks like coated