Rigid Hips Vardhalla dust covers - even harder to find than the originals.
Here's the raw casting ready to roll, they are a bit oversized so they need to be cut down about 1/4" in height to get the correct proportions.
Getting the step on top just right requires a few alu-surgical procedures.
Here comes the scary part, since the covers are really long, cutting this far away from the hub without having the lathe's dub inserted at the top hole is something that requires sobriety of Amish proportions, if you want to avoid vibrations.
More scary cutting, getting the top perfectly flat is important if you don't want to cause unnecessary stress to the material when you bolt them into the fork legs, I added some extra thickness in the castings on top to make them less bound to break over time, something the original Vard INC covers are known to do.
Starting to mill out the side for the top trees.
Made by hand.
One done, one to go...
Cutting away the sides for the lower trees.
Left to right: Raw casting / medium-rare casting / well-done casting.
Made by frozen Yeti hands somewhere inside the frozen thundra of Stockholm, Sweden.