TOPIC:

I know what you are talking about Kawboy. A home made puller. I am just worried about the small bolt size. Even visually 5 mm looks slim against a potentially stuck shaft. I didn't make it to the bike today, but tomorrow I will start soaking it in Kroil. Just in case.

The right cover - I need to get this fixed. I will file the edge to manageable straight lines and fit an angled piece of aluminum to fit it and have it quickly welded somewhere. Does this cover 'aluminum' weld well?
The plan B is making a neat cover from stainless steel, drill and thread a couple holes and be done this way. But since I am going to chrome plate the cover, I'd like to have it done properly.

Which cover is the broken one, Stan?

Regarding the frame and swing-arm, are you going to have them powder coated?

Regarding the alternator cover repair. The wire-guard may be OK if you just "straighten-up" the lines. Don't believe there's anything exotic about the aluminum and think it should weld well. If you choose to have it repaired, someone with some good TIG skills could likely build-up with multiple passes, easier then fitting a piece. For what it's worth.

It's the right alternator cover. The chipped part is that little bit which goes over bundle of wires coming out of it. Nothing wrong with the cover otherwise, very nice. Would be waste not to use it.

Not sure yet about the powder coating. I used paint for outdoor benches or a car grill paint on bike parts, like center stand for example, and they stay strong.

That is a great suggestion Scotch! I feel dumb not thinking about the obvious. I will swing by aluminum welding place not too far away today