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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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After welding in the new sideskirts the fender deformed again
due to shrinkage, this was quite easily corrected by hammering
out the welds with the planishing hammer. The planishing hammer
was also used to raise any low areas and flatten the high areas,
so that almost none of the base material was removed when grinding
the welds.
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Harry wanted the inside contour of the fender to follow the
rim, we taped some 8 mm electrical wire on the tire for the
correct clearance, then used a bit of wood attached to the wheel
axle and with a sharp screw on the other end to scribe a cut
line on both sides.
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We had to remove the beads on both ends of the fender as the
lines were all wrong. Then Aad cut the new inner contour, much
better!
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The sharp corners got a radius, in the next part we will make
a new bead along the edge on both sides and then grind, sand
and polish the whole thing!
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