I decided to make the undertray in two pieces, one upper and one lower. The upper one sits aft of the round crossmember and mounts atop the subframe rails like so:
The notches on the sides are for the passenger seat, so the appropriate bits sit flush with the subframe rails when the seat is installed. The notches toward the bottom of the pic are for the riders seat, so the two hooks can still hook underneath the round crossmember.
Here, the upper portion of the undertray has been drilled and riveted into place, fixing it to the subframe:
I felt if I mounted it atop the framerails in this manner, it would leave me maximum clearance for the cans, moreso than the WOLF undertray pics I've seen to date. I plan to attach some aluminum angle to the underside of the upper part of the tray to enable me to hang the cans from with some band clamps. This is where using 1/8" Al sheet will begin to make sense as it will be a stressed member so to speak, holding the weight of the dual cans.
Now to do something about the forward portion. It needs to run underneath the subframe rails to provide clearance for the rider's seat pan. The plastic seat pan dips below the upper rails and would not clear if the forward tray were mounted up top. Here is the vacancy that needs to be filled. There's an old kid's snowsuit protecting my CF hugger so it doesn't get marred while I'm messing about:
This is the simple piece I wound up with, 1 bend and cut narrower at the leading edge to clear the lower subframe rails. it's clamped in place as part of the fitup and in preparation for drilling and riveting:
It will be riveted to the subframe and to the remains of the stock battery box which has been trimmed and rotated forward to allow more clearance for the Y-pipe that will connect the two mufflers.
I'll have to make a small vertical filler piece to close the gap and have that welded in place to join the two levels of the undertray. Don't want to invite water and road grime through that huge opening, but the Hugger and the dual cans, they should block at least some spray.
I'm planning on removing the whole works this winter and having it powdercoated. For now, it'll stay as raw aluminum. B)