I read quite a few good suggestions here, so I thought I'd ask you folks advice...


I have 11” rear fenders that I need to make 9” wide. I originally planned on splitting down the middle and epoxying a few layers of S glass tape on the inside. Then, I figured it might be easier to cut 2” off the mounting flange/return side. Then, lay the fender on a sheet of highly waxed aluminum and epoxy in a new mounting flange. Which idea would be better? As suggested, I’m using 2”, 4” and 6” S glass tape and epoxy resin.

--Thanks, Chris

Chopping 2" off the mounting flange side initially seems like the easiest/quickest option. The only thing I would be a little concerned about is the arch loosing its shape once the return flange is removed.

If you can somehow hold the wing in position whilst you do the removal and replacement, it should turn out okay as long as the surfaces to be glassed are prepared properly.

Don't you just love the word flange

I think only way is to cut off at the flange side as the taper will be all wrong if you chop it in the middle.

Easy enough to glass in a new flange with matt and polyester resin.

Wax the ali - or even cling film will do.
Put the arch on it and lay up 5 layers of matt.

That will be more than adequate.

Let the 1st 2 layers dry for a couple of days before doing the other three though.

Triton is the guy to ask as the end of the day...

Hope that helps,

Pat...

I would suggest that 5 layers is a little bit overkill, its probably only made with 2 layers anyway. 3 layers will do if you stagger the widths, getting wider each layer.

Thanks for the tips gents. My plan was to outline the fender on the ali before chopping it. I was then going to hot glue blocks of wood to the fender and ali to hold the shape. If I understand correctly, I should just rough up the inside surface with 80 grit sandpaper, then do the layup. Is this right?

Flange, huh. That’s a pretty common word in American English (I think you folks use return). What’s the joke? And while on the subject, WTF is a chav?

Pat: You’re right about Triton; I hope he joins in! You guys gave quite a bit of help just the same.

--Thanks! Chris

quote:

---

Originally posted by chrisf
... And while on the subject, WTF is a chav?...

---

Why not cut it 2" from the flange where it fits to the body then stick it back on top of the old bit with resin and use the same mount face with the same holes. You might have to do a bit of blending in of the leading and trailing edges but it'll save a lot of work.

Making a new flange is the easiest way. I had to make a new flange on my rear fenders, as the were partially tapered, when looking from above, and my car isn't. On my site (August update in diary), you can see more pics of the process. Turned out to be really easy. I used 3 layers of 300 gr/m2 which gave me the same thickness as the old flange. I used wooden block to get the fender in the right shape, after sawing off the old flange.

Good luck!
Marcel

Oh, my site: click here!

[quote]My plan was to outline the fender

why is he drawing a pic of a guitar ??
sorry couldnt resist!!