I'm thinking a stamped stainless sheet metal of nice stiff gauge, then either polish/brush it and chrome it, for two versions. A molded part might be another option but probably overkill. Once a stamping press mold is made, should be easy to crank these out rather reasonably, then have chromed. I'll talk with some friends with experience (or chime in folks). Should be easy to take existing cover, do 3D scan, import to a CNC and have it create some press molds (for how much $$ don't know). Project!
Chuckles


-- RIDE ON -- 2008 America Two-Tone Blue-on-Blue Pictures: http://www.bikebook.ca/bike/v/user/chuckkluz/