Mounting A Custom Rear Fender

After that, I placed the steel piece in the vice and sanded all the edges, removing any burrs and sharp pieces.

Here is what it would have looked like if I kept it. Even after all that work, once I had it on the bike it looked like crap and did not flow. It was as if I was trying to hide something, and I do plan to cover the top of the battery box, so this would have looked terrible.

New plan: first I needed to cut back the fender to see just how long I needed it to be.

I got started cutting through the struts with a cut-off wheel; it was too thick for the plasma cutter.

Then I finished off the cutting of the fender with the plasma cutter.

Then I cut along the side of the fender for the chain to clear.

After the cutting was done, I had to clean all the edges with a sander to remove any sharp pieces and burrs.

Next, I needed to align the center of the fender with the frame.

I had four threaded bungs. All were about three inches long and would work great to mount this fender as long as I ran the bolts from the inside of the fender. So I lined up both sides and marked where I needed to weld the bungs to the frame. Then I spot-welded them in place till I could get all of them in place to make sure that the fender was lined up right.

And here is the other side. I will have two for the right side, but after cutting away the left side, where the chain would be, I only had room for a top one. But I planned to run a strong sissy bar to help.

Next was the sissy bar. I took an 8-foot piece of cold-rolled steel, heated up the middle, and bent it in half.