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After the very good lesson and loss of Part I, it took us a bit to get started on the second fender. One of the big problems with the first attempt was the gap left by the back of the seat to the front of the fender. Since we made the fender right on the rails it went low, unlike the stock fender which bows up to make a much rounder shape, which also fills the gap. I don’t really know why we didn’t try this in the first place, but we used his current fender as a mockup instead of something crazy. We basically (after appropriate masking and such) used a t-shirt and stretched it over his current fender, then painted it with resin. This, because of the immense size and lack of any kind of support matrix was extremely weak by itself, but it was a tremendous step because we got a nice shape.
After letting the shape dry on some beer bottles and toothpicks, we went to work on reinforcing it, making it into something usable. Our goal was another coat of long strand matting and resin on the inside, followed by a metal mesh matrix to add support, with a very thing coat of long strand matting to weave the mesh into the fender and then resin. After the whole supporting and main fender would be done. We’d move on to bondo.
Pics coming soon!
