Mr Noize II:
This is Option 3 from your early post here:
http://rswarrior.com/forums/p/129899/1052681.aspx#1052681 and can be replicated on a common Metal Lathe that has a 3-jaw chuck and 2-1/2" I.D. approx hollow spindle using a thin parting cut-off tool to cut the aluminum tube at a high spindle speed.
Jim aka youngja did an excellent detailed step by step write-up as you know here: Cut down and installed lower fork covers and more using hand tools and his Yankee ingenuity and it came out perfect 
IMHO, the only critical or discriminating tasks of this job (if done on a machinist lathe) is cutting off 3/4" from the proper end and protecting the chrome surface from damage and adhering to Jim's warning regarding the proper direction to file the part w/o peeling the chrome or when removing the masking tape. If inclined, an o-ring groove can be cut as well for a different size ring.
If there are any imperfections on the beauty face this lower tube can be rotated 360 degrees for the best presentation. The only liability here is the quality or adhesion of the chrome plating which is minimized when using the lathe and parting tool.
BTW, hats off to Mr Noize II for setting up a Group Buy from BMS
