Your bike looks awesome! After seeing how clean and sleek the nacelle looks, it now bugs me to look at my stock setup. This is the next mod for my bike.

 

Bugs thats funny that you say that, thats what made me go with the nacelle. After I saw OSDeluxe's ride the front of my bike didn't look right any more. MOCO should make the luxe with the nacelle on it from factory. I think some of the guys on this site would do a better job at designing harleys then Willie G and his crew....haha

 

Thanks Nick...this is exactly what I needed to hear to help me decide the best way to cut this piece without ruining it.

The cover isn't perfectly flat, but might be flat enough to work on a bench. My problems is, in my poor mans garage, all I have is my trusty Dremel. I have had luck cutting chrome pieces with it before (I trimmed some fat off of my old lower chrome belt guard), but this is a lot different.

After reading your advice, I'm getting the feeling that this should be done with professional tools because for 1) It is right in front of the bike, and is going to be one of the first things people see, so if it's not cut right, it will stick out like a sore thumb...2) There needs to be two identical arches cut on each side to flow around the bars, that might be almost impossible with a Dremel.

There are a lot of machine/metal shops in my area and in this case, It may be best to spend a some money (within reason) and have a shop do it.

 

Thanks Bugs...

I felt the same way as you do...it really does change the attitude of the bike. I took a while to save up for it, as these things are, IMHO, way overpriced...but after getting over that, it is worth it.

It really fattens and fills up that front light area doesn't it...brings back that old 50's/60's FL style to our new bikes.

 

Looks great Wish they were not so expensive

 

They will probably use the same method described w/ a high-speed grinder. As you state, find a quality shop. Some can be butchers on delicate items.

You can easily replicate the curvature of each side by making a simple template based from the original piece using cardboard stock (file folder or cereal box material). Simply transfer the outside dimensions onto the template material and trim the curvature of one side (X-acto knife, scissors, etc). Once you've got a clean fit, reverse the pattern for the other side.
You will be surprised how accurate something can be fabricated using the simple trial & error method with a test material.
Once satisfied with the 'clean' template, transfer that onto some self-adhesive contact paper, apply that to the cover, tape as described and shape to size - small increments.
Simple - give it a try!

 

Sweet

 

Sweet look.