Finally, we are making some progress on our rigid chopper project. This time we're cutting and shaping the rear fender to create dimension and give the blank fender shape.
The seat pan had an interesting design we wanted to carry over to the fender, with additional points if it was all matching.
The great thing about this particular task is that you can do all the cutting and shaping with tools you might already have or can get easily.
Follow along as Tracy Spencer from V-Twin City in Santa Ana, California, shows us how to cut a fender the old school way.
The Milwaukee Iron fender...
The Milwaukee Iron fender blank gave us a lot of metal to work with.
Spencer started the shaping...
Spencer started the shaping process by tracing the lines of the seat pan onto a piece of cardboard. He then cut the cardboard template out and outlined the shape onto the fender to get an idea of how it will look.
After clamping the fender...
After clamping the fender to the bench, Spencer used a hand-held band saw to remove a large, unwanted portion of the fender.
He then made the detail cuts...
He then made the detail cuts with a jigsaw, following the contours of the lines drawn on the fender.
Remember that scrap section...
Remember that scrap section of the fender? Spencer cut a few strips of metal off, used a hammer and a dolly to shape them...
...and welded them on the...
...and welded them on the fender edge. This little process adds a whole new look to the fender by adding additional dimension.
Spencer cut the left strip...
Spencer cut the left strip a little too long. A cut-off wheel took care of the extra metal very quickly so he could finish up the weld.
Giving the fender a more complete...
Giving the fender a more complete look, and adding a little strength, Spencer cut and welded a piece of metal to fill in the area near the final drive.
There was a small gap from...
There was a small gap from the outer fender radius to the inset radius, so it was necessary to fill it. Making sure it fit exactly right, Spencer marked where material needed to be removed...
...and ground down the pi...
...and ground down the piece.
With an air grinder, Spencer...
With an air grinder, Spencer smoothed out all the welds to finish up the fender.
A few simple steps and a little...
A few simple steps and a little time was all it took to give the rear fender of our chopper a totally custom look -- plus, almost anybody could do it.