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Workshop => The Mad Scientist => Topic started by: broken1 on May 30, 2015, 04:48:23 AM

Title: DIY fender cutting templates
Post by: broken1 on May 30, 2015, 04:48:23 AM

Got these front fenders in a parts lot with a big chunk missing from the right side. They've seen better days but I wanted to try to salvage them & match both sides, so I made a template out of 1" blue tape:
(http://forums.trx250r.org/vbulletin_imports/322_5442_2017-04-18_1975.jpg)
Drew some witness marks. I started by holding the pencil tight to the plastic & following the contour. It doesn't matter where you put the witness marks as long as the measurements are taken from the same place on both sides:
(http://forums.trx250r.org/vbulletin_imports/322_5443_2017-04-18_9447.jpg)(http://forums.trx250r.org/vbulletin_imports/322_5444_2017-04-18_4513.jpg)
Next I laid down the tape & smoothed it out & transfered the witness marks to the template, than put on a second layer to make it more stable when removing:
(http://forums.trx250r.org/vbulletin_imports/322_5445_2017-04-18_5308.jpg)
Trimmed the edge with an x-acto knife:
(http://forums.trx250r.org/vbulletin_imports/322_5446_2017-04-18_7708.jpg)
Pulled it off, flipped it over & transfered it to the other side lining it up with the corresponding witness marks:
(http://forums.trx250r.org/vbulletin_imports/322_5447_2017-04-18_2188.jpg)(http://forums.trx250r.org/vbulletin_imports/322_5448_2017-04-18_4888.jpg)
(http://forums.trx250r.org/vbulletin_imports/322_5449_2017-04-18_3492.jpg)
Traced the edge & trimmed the pastic with a die-grinder cut off wheel chucked in a B&D drill & finished the edges with sand paper:
(http://forums.trx250r.org/vbulletin_imports/322_5450_2017-04-18_8373.jpg)(http://forums.trx250r.org/vbulletin_imports/322_5451_2017-04-18_6842.jpg)

Title: DIY fender cutting templates
Post by: ESS330R on July 04, 2015, 09:23:36 PM

Came out good!

Title: DIY fender cutting templates
Post by: Big_Mike on July 05, 2015, 01:20:00 AM

Looks awesome!  I plan on cutting mine exactly like your!  Did you use a sawzall, die grinder, hack saw???

Title: DIY fender cutting templates
Post by: Skeans1 on July 05, 2015, 12:51:35 PM

When I trimmed mine I used a router and a flapper wheel on a die grinder.

Title: DIY fender cutting templates
Post by: Pumashine on July 05, 2015, 07:24:51 PM

Sometimes you just have to use what you got. A jig saw works good. If you stand your band saw up it will work also.  Sander belt or flap wheel for finishing/even up

Title: DIY fender cutting templates
Post by: Grande huevos on July 06, 2015, 10:22:01 PM

Quote from: Big_Mike;55788

Looks awesome!  I plan on cutting mine exactly like your!  Did you use a sawzall, die grinder, hack saw???

I used a dremel with a cutoff wheel. It was very easy to control and cut with. It made clean cuts that didn't require hardly any sanding at all

Title: DIY fender cutting templates
Post by: broken1 on July 07, 2015, 01:19:04 AM

Quote from: Big_Mike;55788

Looks awesome!  I plan on cutting mine exactly like your!  Did you use a sawzall, die grinder, hack saw???

I took the cutoff wheel out of my diegrinder & chucked it up in a 3/8" corded drill. I had to be quiet because my boy was sleeping:)