So I just bought a second bike tonight. Going to be a project bike for me. Entering into new territory with customizing. Got a on 883 sportster. So until I'm ready to actually get a fender blank and actually make a bobbed fender for it I want to cut the stock one down some. Mostly so I can utilize spare money elsewhere on parts for now. How is the best way to cut this fender and damage as little paint as possible?

 

Fine grit cut-off disc on a grinder.

 

and lots of tape!! tape the fender where you want to cut it. seal it real good, draw your line on the tape and use the cut off wheel slowly. I would use a die grinder if you have a real steady hand. You will still need to file it smooth, and paint the end. If you can get it in a chop saw, (got to be a good sized one) that will keep your cut straight. Gonna be tough trying to save the paint. What color is it?

 

It is black. I was worried about the heat more then anything

 

band saw

 

If you're trying to save the paint, keep the underside of the fender cool with wet rags, or have an assistant spray down the top side with cool water as you're cutting. Don't get in a big hurry, and you might save the paint. I use a cutoff wheel on an angle grinder, taped on the painted side. Plan on doing a little pin striping along the cut edge.

 

Before and after photos please!

 

Thanks for the help guys. It will be a few weeks before I cut it. Just planning things out at the moment but will certainly post pics

 

+1 on die grinder and lots of tape. It takes longer then you would think to cut the entire fender, I would change sides from left to right during the process. This allows things to stay cool. I did not have an issue with the paint getting hot, or bubbling which seems to be your concern. When done, just file smooth and hit it with some paint.

 

You can also use at some thermal paste