This was much more enjoyable, and felt like it would produce better results. We started the process by using the current Jackpot fender as a base. This was the key different, most of the other stuff was relatively similar. We used saran wrap to completely mask off the fender, and painter’s tape to get the seams. On top of the clear saran wrap we used spray adhesive to hold long strand fiberglass mat in place. We covered the entire fender with the fiberglass matting, the spray adhesive was only to make the next step easier. We wrapped the entire fender in a T-shirt, and to stretch it underneath we bunched up as much as we could and stapled it:

We knew this fender was going to be much shorter than the current one, so we weren’t concerned with making it all the way to the edge, just well over our cutting area:

More or less ready for tons and tons of resin to solidify the whole thing:

Because of how quickly resin becomes gelatinous we had to make it in batches. Approximately 1 cup of resin at a time. If the resin becomes really stringy and semi-jello like, it becomes VERY difficult to work with, but that’s only because of the long strand fiberglass. It grabs it and really moves the stuff around, sometimes clearing entire spots with a single swipe by accident. So, after two batches of resin:

After all the resin is done (for the first coat, anyways) and ready to dry for a looong time. This is the longest drying period, because the original fender is still underneath, which means the saran wrap is still underneath, and once the resin seals off on the outside, the inside takes a tremendously long time to fully cure. We ended up waiting 2 full days and it still wasn’t done, but it was hard enough that we could remove it delicately and let it dry without the backbone.

Still glossy in the next few pictures, but time did pass in between the shots. You can see what I mean about the drying just not happening with the fender still inside:



Finally getting dry to the touch!!

Here are the version 1 and version 2 (alpha) fenders:

The next step is to trim up the shell and start reinforcing it, after all it was still going to be functional as a fully supportive bracket for a passenger seat and a passenger.

On to reinforcing!