Harley Davidson Forums
In the seller's driveway, October 2014.
In the seller's driveway, October 2014.
0 2015/01/22 02:23:01
Crammed In my garage... Now.
Crammed In my garage... Now.
0 2015/01/22 02:23:06
0 2015/01/22 02:23:13
0 2015/01/22 14:58:18
0 2015/01/29 12:43:27
Fenders laid out and marked. What I did was laid one on top of the other to mark the "top/upper" tape line, that way the curves, or roll, of the fender would match up. Quite the fabrication table, hm?
Fenders laid out and marked. What I did was laid one on top of the other to mark the "top/upper" tape line, that way the curves, or roll, of the fender would match up. Quite the fabrication table, hm?
0 2015/01/31 11:46:56
As you can see, I left a little extra on the top side of the spliced donor section. I did this for two reasons: (1) I can always cut more off... And (2) I figured it would be best to tack the "rear face" of the fender first, and then form it to the match the natural curve down. From there, I slipped the skirts of the donor fender into the stock fender, and traced the line that I needed to cut. Broke the tacks loose, and cut the along the line that I traced. This gave me a 100% match-up.
As you can see, I left a little extra on the top side of the spliced donor section. I did this for two reasons: (1) I can always cut more off... And (2) I figured it would be best to tack the "rear face" of the fender first, and then form it to the match the natural curve down. From there, I slipped the skirts of the donor fender into the stock fender, and traced the line that I needed to cut. Broke the tacks loose, and cut the along the line that I traced. This gave me a 100% match-up.
0 2015/01/31 11:47:04
Here are the pieces all laid out... You can see a few of the holes that needed to be plugged.
Here are the pieces all laid out... You can see a few of the holes that needed to be plugged.
0 2015/01/31 11:47:12
Laid out on the side
Laid out on the side
0 2015/01/31 11:47:20
Close up of the section as it was slipped inside, after tacking the rear face. The support brace in the stock fender was kept, but the brace from the donor fender was removed (but is still intact).
Close up of the section as it was slipped inside, after tacking the rear face. The support brace in the stock fender was kept, but the brace from the donor fender was removed (but is still intact).
0 2015/01/31 11:47:27
Another view...
Another view...
0 2015/01/31 11:47:34
After cutting the side skirts, my buddy tigs a few tacks in to set in in place
After cutting the side skirts, my buddy tigs a few tacks in to set in in place
0 2015/01/31 11:47:41
All tacked up...
All tacked up...
0 2015/01/31 11:47:49
Formed and added in some 1/4" round stock for bracing on the inside of the fender. This should give it plenty of rigidity.
Formed and added in some 1/4" round stock for bracing on the inside of the fender. This should give it plenty of rigidity.
0 2015/01/31 11:47:56
All welded up! All holes were plugged, but I kept the rivets in the stock section of the fender in order to keep the "old school" look.
All welded up! All holes were plugged, but I kept the rivets in the stock section of the fender in order to keep the "old school" look.
0 2015/01/31 11:48:05
Fenders laid out and taped up. What I did was laid one on top of the other, and ran the "upper" tape line across both, that way they would be cut in nearly the same spot. Quite the work surface, eh?
Fenders laid out and taped up. What I did was laid one on top of the other, and ran the "upper" tape line across both, that way they would be cut in nearly the same spot. Quite the work surface, eh?
0 2015/01/31 11:57:13
As you can see, I left some extra on the donor fender. I did this for two reasons. (1) You can always cut more off. (2) In order to make sure the "roll" of the fender matched, I slipped the skirts of the fender inside on the sides, tacking the rear face into place. This allowed me to bend and match the roll just right, where I marked my skirts for trimming.
As you can see, I left some extra on the donor fender. I did this for two reasons. (1) You can always cut more off. (2) In order to make sure the "roll" of the fender matched, I slipped the skirts of the fender inside on the sides, tacking the rear face into place. This allowed me to bend and match the roll just right, where I marked my skirts for trimming.
0 2015/01/31 11:57:21
All laid out..
All laid out..
0 2015/01/31 11:57:29
Another view.
Another view.
0 2015/01/31 11:57:37
A close up of the skirts fitted inside the stock fender from the donor fender
A close up of the skirts fitted inside the stock fender from the donor fender
0 2015/01/31 11:57:44
Another view.
Another view.
0 2015/01/31 11:57:51
Tacking everything into place!
Tacking everything into place!
0 2015/01/31 11:57:58
All tacked up!
All tacked up!
0 2015/01/31 11:58:06
Also added 1/4" round stock in for support on the inside of the fender. I also kept the stock bracing in, but removed the brace for the section of the donor fender I used to splice it.
Also added 1/4" round stock in for support on the inside of the fender. I also kept the stock bracing in, but removed the brace for the section of the donor fender I used to splice it.
0 2015/01/31 11:58:14
Finish welds done. I plugged all of the necessary holes, but decided to keep the rivets in the stock section of the fender to keep the "old school" look.
Finish welds done. I plugged all of the necessary holes, but decided to keep the rivets in the stock section of the fender to keep the "old school" look.
0 2015/01/31 11:58:22
All laid out on the nice work surface. In order to run the upper tape line, I laid one on top of the other and taped straight across both. This would ensure that both fenders would be cut in roughly the same place.
All laid out on the nice work surface. In order to run the upper tape line, I laid one on top of the other and taped straight across both. This would ensure that both fenders would be cut in roughly the same place.
0 2015/01/31 12:03:57
Showing the cut section. As you can see, I left a little extra on the donor piece for 2 reasons: You can always cut more off. In order to match the roll of the rear of the fender, we tacked the rear face in place, then slipped the side skirts of the donor section into the stock fender. This allowed us to bend/shape the fender to match the natural curve, and also gave us a solid line to mark and cut the spliced section.
Showing the cut section. As you can see, I left a little extra on the donor piece for 2 reasons: You can always cut more off. In order to match the roll of the rear of the fender, we tacked the rear face in place, then slipped the side skirts of the donor section into the stock fender. This allowed us to bend/shape the fender to match the natural curve, and also gave us a solid line to mark and cut the spliced section.
0 2015/01/31 12:05:21
All laid out.. All of the necessary holes were plugged.
All laid out.. All of the necessary holes were plugged.
0 2015/01/31 12:07:30
Another view before final cuts were made. Once everything was marked, we ground the tack welds off and cut the sections of the side skirt off as needed.
Another view before final cuts were made. Once everything was marked, we ground the tack welds off and cut the sections of the side skirt off as needed.
0 2015/01/31 12:08:03
Close up of the donor piece side skirts slipped inside the stock fender.
Close up of the donor piece side skirts slipped inside the stock fender.
0 2015/01/31 12:08:58
Another view... Side skirts slipped in.
Another view... Side skirts slipped in.
0 2015/01/31 12:09:38
My good friend Nick laying down some TIG. His shop is building about 2 miles of railing for a stadium right now. After they finish that project, they have over 15,000 feet of railing to do for the new MN Vikings stadium. I guess you could say they know how to work with metal..
My good friend Nick laying down some TIG. His shop is building about 2 miles of railing for a stadium right now. After they finish that project, they have over 15,000 feet of railing to do for the new MN Vikings stadium. I guess you could say they know how to work with metal..
0 2015/01/31 12:10:13
All tacked/welded up. I used a piece of round stock and formed it to match the natural line of the edge of the fender. I used the round stock to trace a nice line because I had to trim the skirts all to match up evenly.
All tacked/welded up. I used a piece of round stock and formed it to match the natural line of the edge of the fender. I used the round stock to trace a nice line because I had to trim the skirts all to match up evenly.
0 2015/01/31 12:11:40
I then used the round stock to add some rigidity to the inside of the fender. Formed it to follow the curve and welded it into place. The brace was kept in the section of the stock fender. The donor brace had to be removed. I also decided to keep the rivets in order to preserve the "old school" look.
I then used the round stock to add some rigidity to the inside of the fender. Formed it to follow the curve and welded it into place. The brace was kept in the section of the stock fender. The donor brace had to be removed. I also decided to keep the rivets in order to preserve the "old school" look.
0 2015/01/31 12:13:29
I then added the 1/4" round stock to the inside of the fender to add strength. I kept the brace in the stock section of the fender, but removed it from the donor section. I also decided to keep the rivets for the nostalgic "old school" type of look.
I then added the 1/4" round stock to the inside of the fender to add strength. I kept the brace in the stock section of the fender, but removed it from the donor section. I also decided to keep the rivets for the nostalgic "old school" type of look.
0 2015/01/31 12:16:31
All finished up and ready for grinding, filler and paint!
All finished up and ready for grinding, filler and paint!
0 2015/01/31 12:18:00
0 2015/01/31 12:19:45
0 2015/02/03 17:29:09
0 2015/02/05 05:54:02
0 2015/02/05 05:54:04
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