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Our dear friend Harry is building a new bike based on a Fick
engine (Harley lower end with Matchless heads), and found
a guy in Indonesia to make aluminum fenders for him for a low
price.
Well, I guess something went wrong because the rear fender came
back too small in radius to fit on the wheel! Not easy to fix
because of the deep skirts on the sides, so he came to Aad....
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To increase the radius Aad cut out a large part of the skirts
and then used the homemade planishing hammer to stretch the
middle portion of the fender slightly. The tips of the fender
needed to move 40 mm further apart
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The fender quite quickly expanded the required 40 mm so then
we made patterns to fill up the big holes in the skirts. The
thing with a fender like this is that you can make perfect filler
pieces but as soon as you start welding there will be shrinkage,
which requires more planishing to compensate.
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To avoid visible welds we made filler material for the welds
by cutting slivers off the pieces we had cut out earlier, this
way there will be no color differences
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After checking that the dimensions are stil good we will re-cut
the inside contour to follow the rim exactly and add new beads
around the edges, to be continued...
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