View Full Version : narrowing a fender/ making a bike fender from a trailer

02-27-2015, 10:53 PM
so you can pay 80$ for a 5 inch wide "trailer fender" for a motorcycle or you can pay 15$ for one of these fat biches

http://i1017.photobucket.com/albums/af294/52fargo/03328F89-CDE1-4E8C-B5C2-7B0EB1323643_zpsxodshlvm.jpg (http://s1017.photobucket.com/user/52fargo/media/03328F89-CDE1-4E8C-B5C2-7B0EB1323643_zpsxodshlvm.jpg.html)

measure how wide you want the fender and figure out how much you need to take out of the fender for it to be right, the esiest way to get your marks even is to use painters tape. it comes in 3/4,1,2,4,6 inch wide rolls. be warned those are aproxamite #'s the tape isnt really that width, double check.

anyhow tape it out
http://i1017.photobucket.com/albums/af294/52fargo/0BA103ED-1BB1-4242-B85A-0BB206FD251B_zps3w8q1hmn.jpg (http://s1017.photobucket.com/user/52fargo/media/0BA103ED-1BB1-4242-B85A-0BB206FD251B_zps3w8q1hmn.jpg.html)

http://i1017.photobucket.com/albums/af294/52fargo/18E9EF52-BB76-483C-9032-ECF59D00B9D1_zpserflnfsh.jpg (http://s1017.photobucket.com/user/52fargo/media/18E9EF52-BB76-483C-9032-ECF59D00B9D1_zpserflnfsh.jpg.html)

now using your trusty angle grinder/jigsaw/sawsall/plazmacutter/hacksaw cut the green part out

http://i1017.photobucket.com/albums/af294/52fargo/020_zps2p7qujpd.jpg (http://s1017.photobucket.com/user/52fargo/media/020_zps2p7qujpd.jpg.html)

now hold the two halfs together and tack that shit up, in this case i was replacing a swiss cheese fender so heres a pic of me comparing widths

http://i1017.photobucket.com/albums/af294/52fargo/A5885738-023A-45CE-A3CD-70C939BA4047_zpsrofuk1um.jpg (http://s1017.photobucket.com/user/52fargo/media/A5885738-023A-45CE-A3CD-70C939BA4047_zpsrofuk1um.jpg.html)

now you want to weld it out, you want to avoid putting too much heat in one area or its gonna warp on you so your gonna "stich" it together with a bunch of tacks spaced apart.

your probably looking at your half's thinking "fuck i wish i did a better job cutting on the line, look at that gap, how do i fill that. well you cheat. get your self a peace of brass/ copper. in this case a old thrust bearing from a jgk-4 nat gas compressor because well it was free

http://i1017.photobucket.com/albums/af294/52fargo/D7820F07-ADE7-4C3C-B17E-0DB61CFFAEA8_zpsx8x5hsko.jpg (http://s1017.photobucket.com/user/52fargo/media/D7820F07-ADE7-4C3C-B17E-0DB61CFFAEA8_zpsx8x5hsko.jpg.html)

hold it on the other side of your fender across/bridging the gap

http://i1017.photobucket.com/albums/af294/52fargo/025_zpspqpij9wq.jpg (http://s1017.photobucket.com/user/52fargo/media/025_zpspqpij9wq.jpg.html)

then put your tack on top of it, the weld will stick to the sides where it melts in but wont stick to the brass, once welded clean that bitch up and test fit

http://i1017.photobucket.com/albums/af294/52fargo/027_zpsqqr0rjg6.jpg (http://s1017.photobucket.com/user/52fargo/media/027_zpsqqr0rjg6.jpg.html)

trim to length and drill your mounting holes
http://i1017.photobucket.com/albums/af294/52fargo/094_zpsb59r94o2.jpg (http://s1017.photobucket.com/user/52fargo/media/094_zpsb59r94o2.jpg.html)

ta fucking da you have a fender, and a built not bought fender at that

you can get as crazy as you want add ridges, flair the end what ever, in no crazy metal worker all ive done is the fender for one of my other bikes i flared the end and used the steel i cut outta the inside to make some mounts

http://i1017.photobucket.com/albums/af294/52fargo/EEBA967E-5B09-4F0A-A24D-57B5CD99A445_zpsuwoe3qlz.jpg (http://s1017.photobucket.com/user/52fargo/media/EEBA967E-5B09-4F0A-A24D-57B5CD99A445_zpsuwoe3qlz.jpg.html)

http://i1017.photobucket.com/albums/af294/52fargo/E138D8C7-F360-4548-B25D-4C6ED8FA5054_zpsuwzy0f4e.jpg (http://s1017.photobucket.com/user/52fargo/media/E138D8C7-F360-4548-B25D-4C6ED8FA5054_zpsuwzy0f4e.jpg.html)

http://i1017.photobucket.com/albums/af294/52fargo/FE8CEFEC-1297-4130-A889-A73675237F40_zps0xj3vh2h.jpg (http://s1017.photobucket.com/user/52fargo/media/FE8CEFEC-1297-4130-A889-A73675237F40_zps0xj3vh2h.jpg.html)

now go build some cool shit

03-05-2015, 10:40 AM
This is a awesome write up man. Thanks for the info. Can you show, or describe how you put the dove tail / flare out on the fender?

03-05-2015, 2:23 PM
mark a line across fender where you want the bend, cut the sides of the fender up to the flat top, bend however much you want it flaired, hold peace of cardbord inside, mark out how big of a triangle is open, use that as a template cut out a fill peace and weld her in

03-05-2015, 2:54 PM
Nice write up man, I will keep this in mind for my next build.

03-07-2015, 1:17 PM
Very nice bro.

04-15-2015, 7:45 AM
Where did you buy your fender for $15?

04-18-2015, 12:09 AM
princess auto. im up in Canada so prices may vary

04-20-2015, 10:22 AM
Found my fender at a local tractor supply for $25

12-14-2015, 12:36 PM
Killer write up. Thanks man.

12-15-2015, 8:20 PM
Right on time for me! I'll be attempting a fender this weekend. Thanks

12-17-2015, 1:46 PM
I got a fender from northern tool last night for $25. Did the tape method and cut it with an angle grinder. My lines were pretty haggard. I took the strip that I cut out and tack welded it along the entire seem underneath. I filled in what I could on top and will finish the rest with some metal to metal filler.

12-31-2015, 5:00 AM
Hey man great read.. I was in tractor supply yesterday, and I saw the trailer fenders.. I've been pondering on what to do with the one flat side.. Great ducking read. Diy 4 life!!