+1 on the 3m cut off wheels, you may want to make a few practice cuts on some sheet metal of about the same thickness as the fender just to get used to the cutting tool

 

i was serious about the tin snips by the way. i have been doing sheetmetal work since i was about 17, with the snips there is no heat/friction and nothing to burn the paint. if you lay the masking tape where you want to make your cut, make your line with a sharpie and trace that line with the snips. peel your tape and, bingo bango who wants to buy a doughnut? but honestly any of these options will work, but i think the best tool is determined by the person using it. good luck and share some pic's when its done!!

 

Electric angle grinder with a cutoff wheel. I did this using a Dewalt but that $15 Harbor Freight model will probably do the trick. There's not much to a fender. Take your time and keep a steady hand. Make sure you cut on the discard side of the line.




Smooth up to the line with a file. Oh, and make sure you wear eye protection. Goes without saying...just a friendly reminder.

Here's a pic of the grinder I used.


Here it is in action. Not the fender but the principle's the same.

 

Thanks folks all good advice!

May tackle this over the winter.

I've heard mixed advice on taking the fender off or leaving it on during the chop. Thought?

I guess I also Need to make myself comfortable with wiring a light relocation of course.

I've already got some touch up paint in case I need it after the chop.

 

I'd take it off. Easier to do it when you can attack it from just the right angle and make a smooth cut without worrying about hitting anything else. Especially if it's a winter project and you have time to play with it.
Just my 2 cents.

 

if you are going to put it on your xmas list you might as well get a Foredom...just sayin'