Finally some serious progress. This is a shot of the primary cover all bagged up and curing.
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And this is the cover after removing from the mold, and a little bit of trimming. There are a couple places where it didn't get pulled all the way into the mold, because I didn't fit the bag material with enough extra to conform to the shape. Live and learn. It's not bad, and I think I can fill in with resin in a few places, and it will still be good enough to look good with a couple coats of clear.
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And this is what it looks like with a little trimming and mocked up on the bike.
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It looks a little large to me, but it is a pretty close fit on the alternator, so I don't think I could have made it any smaller. I still need to trim it down to a small flange, and make make mounting brackets, but that should be pretty simple.
Ken