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Thread: High fender mod

  1. #1
    Senior Member Trail Woman's Avatar
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    High fender mod

    Hey!

    Just finished my high fender bracket and install. Super excited!

    So made up a template with cardboard and re drew it in adobe illustrator. The circle was intended to be a drain hole but I decided to wait until later to decide where to put it if it proves to be needed. Printed it out and spray adhesived it to a L channel of aluminum I ordered from aircraft spruce. The best place I found to order fabricating materials in Canada.
    bracket 1.jpg
    I cut it out with band saw, files, belt sander and steel wool. The paper can be difficult to remove even with a heat gun and varsol. I used lepage general purpose and generally it will heat release with a heat gun. You'll want to make sure not to overheat your piece when cutting or the template can shift.
    bracket 2.jpg
    I neglected to leave enough room for the bolts so I had to get creative with countersinking them which is fine since it allows more wheel clearance. I also found I needed to make spacers to get the bolted area clear of the forks. I also needed 1/2" longer bolts. The fender I ordered from fortnine.ca
    bracket 3.jpg
    And the end result..love'n it.
    bracket 4.jpg
    Now I've been told welcome to owning a dirtbike. lol
    bracket 5.jpg
    Considering painting the bracket dark metallic grey like the rear plastics/gas tank and have to update my Winona's make over thread with her latest look.
    Last edited by Trail Woman; 01-28-2018 at 03:03 PM.

  2. #2
    Member TPearce's Avatar
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    Looks Good!
    littletommy and Trail Woman like this.

  3. #3
    Member BearScat's Avatar
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    Quote Originally Posted by Trail Woman View Post
    Hey!

    Just finished my high fender bracket and install. Super excited!

    So made up a template with cardboard and re drew it in adobe illustrator. Printed it out and spray adhesived it to a L channel of aluminum I ordered from aircraft spruce. The best place I found to order fabricating materials in Canada.
    bracket 1.jpg
    I cut it out with band saw, files, belt sander and steel wool. The paper can be difficult to remove even with a heat gun and varsol.
    bracket 2.jpg
    I neglected to leave enough room for the bolts so I had to get creative with countersinking them which is fine since it allows more wheel clearance. I also found I needed to make spacers to get the bolted area clear of the forks. I also needed 1/2" longer bolts. The fender I ordered from fortnine.ca
    bracket 3.jpg
    And the end result..love'n it.
    bracket 4.jpg
    Now I've been told welcome to owning a dirtbike. lol
    bracket 5.jpg
    Considering painting the bracket dark metallic grey like the rear plastics/gas tank and have to update my Winona's make over thread with her latest look.
    Very nice! Loving the round headlight also.


    Sent from my iPhone using Tapatalk

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  5. #4
    Super Moderator littletommy's Avatar
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    And if you think the front of your engine looks dirty now...just wait.
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  6. #5
    Senior Member Trail Woman's Avatar
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    Haha..I might have to start cleaning it.... to keep the weight down.

    Next is the shinko sr241 and the 244 is going on the back of the xr250.

  7. #6
    Senior Member Heli-Mech's Avatar
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    Very nice!

    Aircraft spruce is a great place .... locall try metals r us in burnside for material .... they have "off cuts" racks of material out back that you can search through.

    I've seen many an aircraft part made by "profesionals" that aren't as nice as your bracket. Nice finish work.
    Trail Woman and TopPredator like this.

  8. #7
    Senior Member Trail Woman's Avatar
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    Quote Originally Posted by Heli-Mech View Post
    Very nice!

    Aircraft spruce is a great place .... locall try metals r us in burnside for material .... they have "off cuts" racks of material out back that you can search through.

    I've seen many an aircraft part made by "profesionals" that aren't as nice as your bracket. Nice finish work.
    Thanks! My shop practices started off more as art then utility but incorporating both is even more rewarding. I've heard about metals r us but I don't get into town for months at a time. I may have to pop in next time though and pick up commonly used materials if the prices are that good.

  9. #8
    Senior Member Heli-Mech's Avatar
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    Quote Originally Posted by Trail Woman View Post
    Thanks! My shop practices started off more as art then utility but incorporating both is even more rewarding. I've heard about metals r us but I don't get into town for months at a time. I may have to pop in next time though and pick up commonly used materials if the prices are that good.
    Just ask to see the off cut racks they have them organized by material/length etc .... and they have gift cards!

    Sent from my SGH-I337M using Tapatalk
    Trail Woman likes this.

  10. #9
    Senior Member Lyterx's Avatar
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    Quote Originally Posted by Trail Woman View Post
    Hey!

    Just finished my high fender bracket and install. Super excited!

    So made up a template with cardboard and re drew it in adobe illustrator. The circle was intended to be a drain hole but I decided to wait until later to decide where to put it if it proves to be needed. Printed it out and spray adhesived it to a L channel of aluminum I ordered from aircraft spruce. The best place I found to order fabricating materials in Canada.
    bracket 1.jpg
    I cut it out with band saw, files, belt sander and steel wool. The paper can be difficult to remove even with a heat gun and varsol. I used lepage general purpose and generally it will heat release with a heat gun. You'll want to make sure not to overheat your piece when cutting or the template can shift.
    bracket 2.jpg
    I neglected to leave enough room for the bolts so I had to get creative with countersinking them which is fine since it allows more wheel clearance. I also found I needed to make spacers to get the bolted area clear of the forks. I also needed 1/2" longer bolts. The fender I ordered from fortnine.ca
    bracket 3.jpg
    And the end result..love'n it.
    bracket 4.jpg
    Now I've been told welcome to owning a dirtbike. lol
    bracket 5.jpg
    Considering painting the bracket dark metallic grey like the rear plastics/gas tank and have to update my Winona's make over thread with her latest look.
    Would you be able to send me a copy of the file? I could draw it up and save it as a dxf or dwg file that could be made available to members? Or make a printable one with dimensions?
    Fred and Trail Woman like this.
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  11. #10
    Senior Member Fred's Avatar
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    Lyterx, the top profile would need a little tweaking in order to match the OEM rectangular headlight, cowling and retaining bolt, etc. Very doable if artist author wants to share her intellectual property Nice offer, a great way to take TrailWoman's good work further.
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