First modification to make was to cut out the existing caliper cut out to make a smooth line for a replacement patch. Using 16 gauge weldable steel sheet I held it up under the uncut side and traced the flowing sweep of the bottom of the fender. Then I held it up under the new cut out and traced a line to meet the outside sweep. Using the plazma cutter I cut just outside this line and ground off the rest with an angle grinder. The plazma cutter contaminates the steel for welding and must be trimmed. here I am at work in the garage!!
Here is the new filler piece.
Using several vise grip clamps I pinched the filler into place and tac-welded it in several places. I kept tac-welding, moving left-right-center-left, etc until the clamps were in the way. I didn't want to get these plates too hot to where they would warp. Here is the welded fender and where I left this project in limbo last week before getting ill. Should make some headway tonight.
Next I get to weld the inside of the skirt fully into the fender and grind all these welds flush and then sand them smooth. Guess I need to remember to weld those stock holes shut as well. Then I drill the other side for mounting onto the forks and trace the caliper lines out for trimming.
Since there is about 1/4" space extra between the fender and forks, I figured I would make some heavier plate brackets to support the fender and take up this gap. Here is a cardboard mock-up I am getting ready to trace out on the 1/8" plate. These will ride against the fender and bolt to it in three places as well as the stock two screws running from the inside of the fender to mount it to the forks. Here is a plan to show what I am thinking. I would like to chrome these struts.
Fender Strut shown Blue
Last night 3/7/2005, I finished welding up the fender skirts, all the excess holes, and ground all the welds down.
In the picture above you can see the traced caliper cutout and
all the ground welds and holes I had to fill.
A few seconds with the plaz cutter and a hole is born (shown below). It will
take several fitting and grinding sessions to
get this opened up to where I can fit the caliper in there.
Below is a good shot showing how tight I am making this cutout for a seamless look.
A 1/4" of space is left between the disc and the fender.
I may decide to weld in some bar stock inside the fender to
add some rigidity.
Here you can see the extra space between the forks and the fender. This is why I am building the struts.
Here is the first cutout fender strut. It is in ruff condition
but I will get to drilling it and then sanding it
to get it nice and smooth and shiny...then get it chromed. I think I will use
chrome Allen-head tapered
flush mount bolts to secure it to the fender. This was the trace from the
cardboard cutout earlier.
I used the angle grinder to shape it and then the bench grinder to even the
curves.
Next I used the first strut to trace the second. Trace wide and trim inward!
Here are the first and second shown together. Second is
freshly cut with the plaz. time to call it a night. It is 12:30.
I put a good three hours into this nights projects.
Here are some mounted fender pictures. Lots of sanding left to
smooth everything out,
maybe a little bondo for some divits, and then on to the rear fender!
Update 3-11
Fender struts are complete, drilled, edges smoothed, sanded,
and ready to go to the chromer.
Fender is rigid as I'll get out, with these struts in place.... Thinking about
redoing them with some struts
cut out like flames, but I will wait til after the paint to see if they would be
too much flames.
Fender Project Page 1 Rear Fender Project Page 3
Gonzo
02' Shadow Spirit