I made this out of 14G steel for the simple reason of i can weld it, unlike alum. Turned out great i think, especially for not having any money in it.
Metal was scrap from work. I made one out of carboard first to get ballpark degrees for the bends. I had the local metal shop put the 3 bends in it. Otherwise it was all done with cutoff wheels, grinders etc...
I used a holesaw kit to put the holes in it.
I used bedliner for the finish on the outside and high temp paint on the inside since its close to the exhaust. Sorry for the very dirty bike.. its a mud pit around my house.
I've added below specs on this pan. Feel free to use them to give yourself a guide to make your own. There are A LOT of variables in this that will change the dimmensions so i encourage you to mock one up with cardboard to see how your application affects the dimmensions.
But this will get your in the ballpark for sure. Soem of those factors are: What crash bars your have, how close to the crashbars you want to mount it, what brackets you use, how close you want the it to be to the exhaust, how far back you want it to go etc.. etc...
Once you cut out your pan(with no sides on it) mount it up first. Its super easy to bend 14G steel with no sides on it, this way you can tweek the bends to meet your mounting points. Once its all mounted up and bolt tight, then tack on your side pieces while on the bike so you maintain your bends, otherwise they may change when you weld on the sides.
Just for the record i have:
Givi Crash bars, and a Hepco Becker centerstand
The top of my pan(as you can see in the pics) is mounted up super tight to the Givi crash bars. I also notched it out to clear the Givi mounting bolts in the front. You can change that any way you like of course.
I made my rear mounting bracket out of 3/16" steel. This bracket will change dependig on your desired mounting position. I mounted mine really close to the engine with about 3/4"-1" clearance between the pan and the exhaust.
My sides are 4" tall and that is just a personal preference and can easily be changed to your liking. There is a huge variety of ways you can make your sides. I made mine with 4 different pieces. Then welded them from the backside letting the weld penetrate to the front. Used a sand flap disc to smooth it all out. Then filled any little divits on teh front side with a tack here and there. Once thats done i used truck bed liner to coat it and that gives it the appearance that the sides are all one peice. You could of course weld the seems on both sides, doesn't matter just whatever you prefer.
I used three sizes of hole saws to get my holes. 2", 1 5/8", and 1 1/8"
I added a few water drain holes in the bottom of the pan, and a hole to allow me to drain the oil in it without removing the pan.