I screwed up my stock fender on my 48 & ordered another 1. I'm wanting to cut about 2.5-3" off it before I have it painted. I want it to have the same contour as it is from the factory, just shorter. I tried cutting my old fender w/a Dremel & a 4" cut-off wheel on a grinder. The Dremel made a nice straight cut but I can't make a radius w/it. The grinder was a mess! So can I use a metal blade in a jigsaw to cut rear fender or will it bounce all over the place? Thanks.

 

Yes, a fine blade in your jig saw will work ... that is what I used to cut my fender. After removing the fender and drinking a beer I cut the frame rails, then reinstalled the fender. I wrapped the fender with blue painters tape, created a template and traced out what I wanted. Drank a second beer and let the jig saw rip !!

 

I used an airsaw. It's really not that difficult.

 

FYI - You will need to raise the rear of your bike to clear the saw blade. I removed my rear wheel. Bolting the fender on the bike is a good way to keep it steady while cutting vs. getting someone to hold it for you.

 

I took the long route due to most of my tools being in storage at the time but it turned out fine...I taped off the area, used a hacksaw and cleaned up everything with some metal files. It turned out pretty well. I'll post a picture soon.

 

So it's a 2 beer job. Got it!

 

I tried a jig and after bending three blades, switched to a circle grinder. That made it a lot easier in my opinion.
+1 on the metal file to take the edges off.

 

That is a cool looking rear fender!!!!!!!

 

Thanks ... good to hear that you like. Hard to see in the pics, but the sides roll rearward with a sight radius along the top. I cut it that way to make the fender more interesting than a straight line from end to end.

 

Good ol hacksaw worked for me