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Old 03-10-2009, 04:38 PM
Scored: 10
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Fender Bender: A Lesson in Metal Shaping.

I marked the exact location where the tabs would be welded to the fender. With a hammer and a home made dolly ( a table top would work the same) I flattened out the bead where the tab would be welded in, not the entire weld, just the bottom half.

Once the two pieces fit the way I wanted them two, I welded the tabs to the fender, and finished the weld out the same as the long weld down the fender earlier.

The only thing missing at this point was some type of mount for the bottom front. We decided on a single mount in the center at the lowest point, it would be underneath the seat and clean. I bent up probably one of the smallest boxes I have ever made on the box brake, cut a notch out of the fender and fit it in place, welded it in and drilled a hole in the center for the bolt, slightly over sized for fender alignment adjustment.

The mount on the frame is tapped, a bolt from underneath will secure it.

And there you have it, a scratch built fender from start to finish. I'm not able to show the rest of the bike yet, but Rootbeer Float will be starting a build thread on it shortly, I did the tank and some other misc. fab work for it also, so keep looking for it.

I hope I've done a decent job at making metal shaping a little less of a mystery to those who read this article. I've always been upset that most all the articles I've ever seen in magazines tell you little about the science behind it, they just seem to show someone using an english wheel and saying "it was shaped on this". Now you know what it's actually doing. Maybe you'll have the confidence to try a project on your own, or at least now maybe you know where to begin your next project. If your genuinely interested in learning and becoming a professional, or have a shop and want to send yourself or employees to someone to learn or improve your skills, there are a few people out there teaching. I recommend one above all, my mentor and friend Fay Butler, ; What you will learn from his seminar in three days will change your life forever. Browse his sight for more information and helpful tid bits, you'll be surprised what you can find, and while your there, browse through the pictures of "past seminar participants, you may be very surprised to see some of the names that have been to him, including others who now teach! Now, get some sheet metal and start experimenting!

Mark Usyk (Oilburner)


Last edited by Ace of Spades; 04-28-2009 at 05:38 PM..

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Old 05-12-2009, 09:01 AM
CC Member/Contributor
Awesome Oilburner! thanks for all the info and pictures too. For me this has always been interesting and your article took alot of the mystery out of it. --Drew
Old 05-12-2009, 11:12 AM
Club Chopper Member
fuckin cool ! bravo !
Old 05-12-2009, 06:43 PM
Club Chopper Member
Glad to see some feed back posted up, thanks guys. I wanted to really explain what was going on so maybe people would get something out of it more than just "he used an english wheel and this shrinker thing". I'll answer any questions anyone has about the process if something isn't clear. Mark.
"I go to bed at 10 now".
Old 10-07-2010, 04:06 AM
Club Chopper Member
OMG This post sucks! now I have to go invest in an english wheel, bead roller, and shrinker!!!! LOL

Just kidding about the suckage... very nicely don sir!
Old 06-06-2012, 10:45 PM
Club Chopper Member
Mark that's a great write up and pictures. I appreciate how long that must have taken besides actually making the fender. Thanks lots. I know a bit about machining and welding after 25yrs in the game but sheet metal work is out there.
I now have more of an appreciation of just how specialised those skills are.

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