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Old 03-20-2007, 10:20 PM   #1
crimescene
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Default Making an ugly fender a little more interesting...

On my quest to piece together a shop bike without spending any real money, I started modifying the rear gender on this ironhead I picked up two weeks ago.

This is the before picture, I've been re-doing the tank in this thread: http://jockeyjournal.com/forum/showthread.php?t=14934. The tank just needs the petcock bung, tank seal and paint. The tail light is going to a new home, to be replaced with one of Fab Kevin's "doubleshot" sidemounts.

Now the fender isn't that bad, but it is a little flat across the bottom and kinda booring.

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Old 03-20-2007, 10:24 PM   #2
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Default Re: Making an ugly fender a little more interesting...

My idea is to add a fin-detail to the fender, and to trim the back into a little more of a radius. It isn't the perfect solution -- I'd rather hardtail it and make a new fender -- but I want to have this back together next week or the week after at the latest.

I made up a chipboard pattern of the profile I wanted.

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Old 03-20-2007, 10:27 PM   #3
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Default Re: Making an ugly fender a little more interesting...

This is a little better angle.

The metalflake-diamond tuck seat isn't working for me. I sent the pan out to Martin at Dream Evil Design to be recovered. Yes, that is real money being spent, but that and the paint supplies are the only things I don't have laying around here.

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Old 03-20-2007, 10:31 PM   #4
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Default Re: Making an ugly fender a little more interesting...

I made a "template" of the fender radius first using some 1/4" aluminum round bar. Then I used that to lay out the chipboard template. While the template was taped in place I sketched the "footprint" of the fin on the fender (e.g. the width). I measured from the edge of the fin to the top to get the height of the blank (since it will angle in).

I cut two blanks, tacked them on the edge, then spread it apart and worked the shape with hand tools until I liked the taper.

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Old 03-20-2007, 10:34 PM   #5
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Default Re: Making an ugly fender a little more interesting...

The previous owner had some funky stuff under the hammertone paint, so I took care of those sins, trimmed the fender, laid out a centerline and tacked it in place.

Once it was tacked I decided to make the sides of the fin concave, so I worked it with a hammer to dish them in.

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Old 03-20-2007, 10:36 PM   #6
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Default Re: Making an ugly fender a little more interesting...

Another view.

It just needs to be welded up and ground smooth (and a small cap made for the front) and this will be done too.

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Old 03-20-2007, 10:37 PM   #7
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Default Re: Making an ugly fender a little more interesting...

Dang. Nice work.
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Old 03-20-2007, 11:18 PM   #8
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Default Re: Making an ugly fender a little more interesting...

Nice work, Joe. Your tech updates are realy good. Cant wait to see how this bike turns out. You plan on modifying anything else on this project?
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Old 03-21-2007, 12:55 AM   #9
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Default Re: Making an ugly fender a little more interesting...

Quote:
Originally Posted by Halseth
Nice work, Joe. Your tech updates are realy good. Cant wait to see how this bike turns out. You plan on modifying anything else on this project?
The exhaust for sure, it is an old 2-into-1 setup. Not loud enough, sounds weird. I have some kinda crazy exhaust tips in mind for it...

Several bolt-ons will be added: Fab Kevin points cover and doubleshot tail light, After Hours Choppers brass risers, Dream Evil seat and tool bag. This wasn't suppossed to be a project
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Old 03-21-2007, 12:57 AM   #10
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Default Re: Making an ugly fender a little more interesting...

OK, it's all welded and ground. I need to do a little detail work before it gets prep'd for paint...but this is 99% done.

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Old 03-21-2007, 01:00 AM   #11
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Default Re: Making an ugly fender a little more interesting...

Last shot of the fender. I already sent the seat off to Martin at dreamevildesign.com so it looks slightly weird -- but it should work pretty well (visually) with the seat in place.

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Last edited by crimescene; 03-21-2007 at 09:08 AM.
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Old 03-21-2007, 06:04 AM   #12
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Default Re: Making an ugly fender a little more interesting...

thats sweet. reminds me of a stingray's tail. nice work!
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Old 03-21-2007, 07:36 AM   #13
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Default Re: Making an ugly fender a little more interesting...

Man, between the fender and the tank, you are one crafty individual. Can't wait to see what's next.
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Old 03-22-2007, 12:39 AM   #14
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Default Re: Making an ugly fender a little more interesting...

thats awesome
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Old 03-22-2007, 01:27 AM   #15
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Default Re: Making an ugly fender a little more interesting...

you have the BEST tech threads on this board. they are very much appreciated. thanks.
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