I thought I'd share a few photos of the grab rail caps/plates I made. I planned on taking photos for a step-by-step, but completely forgot to take any of the first few steps.
Here is the finished product and a picture of when it was primed to kind of show you the thickness. It's not bolted on because I am in the process of trying to find a metric bolt that is a little more aesthetically pleasing than the originals. It gives you an idea though.
Basically I took the stock grab rail and used an angle grinder with cut-off wheel to cut the top part of the grab rail off. I left it about 3/8" because it is a little easier to remove the metal than add it back on, obviously. I then ground them down to 1/4" with the grinder. For the low spots (since I couldnt' grind it perfect) I used JB Weld to fill it in. I globbed it on there quite thick.
After the JB dried I sanded with a coarse emery paper screwed onto a chunk of 2x4 to ensure it would be nice and flat. Once I started getting down to the aluminum, I sanded until the top was approx. 3/16". I still had a couple low spots so I mixed up more JB a spread it out using and old ID card to help keep it somewhat flat.
After everything was filled, I sanded with a medium and fine emery cloth. For final sanding I wet sanded using 400 grit wet/dry. I cleaned it good with paint thinner then primed... then sanded and primed and sanded and primed until any deep scratches were out. Went over it with a primer sealer and top coated with Dupli-Color Truck, Van SUV paint. The color is T414 Storm Gray. I was trying to get a match as close to the gray color of the Honda wing on the tank and the 919 on the cowl. It's not perfect but close enough for $4 rattle can. The project isn't top quality, there are some flaws, but for the tools I have and my lack of patience I think it turned out pretty good. Any comments good or bad will be appreciated..... Well maybe the bad ones won't be. Thanks