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Thread: Making fenders.

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    Default Making fenders.

    Sorry if this is the wrong forum, but I couldn't think of a more fitting one.

    I have some aluminum scrap I'm hoping to make compound-curved fenders out of, complete with rolled edge, but I don't have a roller, english wheel, power hammer, or anything like that, let alone knowledge of how such things are actually done. Instead I have pieces of hardwood I've shaped with hopes I could hammer the aluminum into fenders around, but I'm completely failing as I suspected I would. Does anybody have experience making metal fenders, or even an understanding of some processes used by manufacturers?

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    Default Re: Making fenders.

    I've seen old fender rollers for sale before, maybe VAR made them?

    Fender Rolling 101
    steve cortez

    FNG

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    Default Re: Making fenders.

    Quote Originally Posted by fat cat View Post
    Sorry if this is the wrong forum, but I couldn't think of a more fitting one.

    I have some aluminum scrap I'm hoping to make compound-curved fenders out of, complete with rolled edge, but I don't have a roller, english wheel, power hammer, or anything like that, let alone knowledge of how such things are actually done. Instead I have pieces of hardwood I've shaped with hopes I could hammer the aluminum into fenders around, but I'm completely failing as I suspected I would. Does anybody have experience making metal fenders, or even an understanding of some processes used by manufacturers?
    A

    Anneal the material

    Look at how they used to make coatings or panels the old handmade way


    Truly soft aluminium will form over wood beautifully

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    Default Re: Making fenders.



    Not a fender, but apply what he does to the aluminium.

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    Default Re: Making fenders.

    Probably a dumb question, but what type of rod and flux is he using to gas weld aluminum? I doubt I'd trust that on a bike but that is cool.

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    Default Re: Making fenders.

    Form & pound it with a soft hammer over and old car wheel.
    - Garro.
    Steve Garro, Coconino Cycles.
    Frames & Bicycles built to measure and Custom wheels
    Hecho en Flagstaff, Arizona desde 2003
    www.coconinocycles.com
    www.coconinocycles.blogspot.com

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    Default Re: Making fenders.

    Quote Originally Posted by seankanary View Post
    Probably a dumb question, but what type of rod and flux is he using to gas weld aluminum? I doubt I'd trust that on a bike but that is cool.

    This guy carries a lot of the necessary supplies for gas welding aluminum. He uses it to mostly build airplanes and automobiles,

    https://www.tinmantech.com/html/alum...g_supplies.php

    Alistair.

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    Default Re: Making fenders.

    Quote Originally Posted by Alistair View Post
    This guy carries a lot of the necessary supplies for gas welding aluminum. He uses it to mostly build airplanes and automobiles,

    https://www.tinmantech.com/html/alum...g_supplies.php

    Alistair.
    I was also going to suggest Tinman for ideas and info on forming the alu fenders. Check out his youtube videos for forming ideas.

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    Default Re: Making fenders.

    this was the video i was looking for



    scale it down some and voila....torchwork = annealing

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    Default Re: Making fenders.

    No fender exists that will fit my 20x2.4 tire, so I had to figure out how make them myself. Here is the blog post I wrote about it recently:
    https://drewdevereux.wordpress.com/2...cycle-fenders/
    They are hybrid aluminum/wood fenders. The post may be interesting to a DIY type who has access to a table saw and can do (or learn) some hard-soldering.

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    Default Re: Making fenders.

    I've experimented with 3D printing fenders....YMMV.

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