Buy some mesh this one was good enough to make 3 rad guards:

http://cgi.ebay.co.uk/ws/eBayISAPI.dll? ... 0353576408

Then some edge trim:

http://www.woolies-trim.co.uk/c-330-pvc-edge-trims.aspx

Part no 304 Titanfast Edge Trim (I bought 4m)

Cut the ali using sharp scissors 342mm x 193mm.

Fit the trim round the edge and close using a vice to close the metal sill so it stays in place.

Using this measurement it does not need any tie grips just fits securely enough and as its a half moon it pushes back on itself securing it.

Can easily be painted black if needed and has no probs with rad temp.

Thanks to KTM worship on sourcing the sill. ) have put them both on my bike and fit very snugly. Believe all rad's are same size.

Nice job Superdan, PM sent!

hmm, even with 20-25 pounds shipping, I'm tempted. Save me the trouble of getting the stuff here.

it weighs less than 200g and can be sent as a letter. Royal Mail states it should be around 6 GBP so 16 GBP in total

yeah but it would be dented and folded, battered. ...Just not the kind of thing you can send in a padded envelope.

Maybe, the ali was sent to me with wood and foam protecting it can do likewise, just weighs twice as much lol I guess for what it costs is it worth it!