DIY fender cutting templates

[broken1]

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:

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:

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:

Trimmed the edge with an x-acto knife:

Pulled it off, flipped it over & transfered it to the other side lining it up with the corresponding witness marks:


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:

[ESS330R]

Came out good!

[Big_Mike]

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

[Skeans1]

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

[Pumashine]

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

[Grande huevos]

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

[broken1]

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:)