Part 4 Suzuki DR650

So remember when I said I didn't have a plan? Well that was really dumb....
I was trying to get things symmetrical on both sides of the fender and trying to work out the bottom edge and it wasn't going good...Then this happens.

I flipped the fuck out and tore off the clay and ripped that hateful bull shit off the bike.
I reached a low point and considered just buying the $165 dollar pre-made straight fender.
Then after I cooled down I said, "This is customfighters for fuck sake that's not how we do it here!"
So a plan was hatched. Yes now I have a plan... Center line and outside edges of fender mark out on a Ikea furniture laminated board type of thing and fender piece aluminum taped down.

Shit ton of card board and aluminum tape to cover the hole and build the fender tip piece up some.

Starting to get sick of it, but I can see the light at the end of the 'ol tunnel at this point. I will see this through, it may turn out to be crap... But I will see it through.

Then add a fuck shit stack of aluminum tape with packing tape over that layer.

Next post will be an actual fender, I promise..
But for now one more on the mold.
Pop the mold off the board.

Sand with 80 grit.
Freaking wavy gravy.

Bondo (or "bog" if you ain't from 'round here) and sand then repeat. And repeat. And repeat...
Lighter bondo is normal two part, darker red is spot glaze.

Mold primed, black painted (helps to see air bubbles when laying glass), clear coated.

Coated with a light coat of vasoline to help with release.

First layer of fiber glass is the woven cloth, then added three or so layers of loose strand mat.

Pop the fender out of the mold. Killed the mold in the process though. I'll talk about that in discussion thread. Drill a hole for back mount and counter sink.

Front mounts drilled and nut...thingys mounted on.

Cut off grab handle mounts. Didn't want them on the bike or the holes on the side of the fender.

Will clean up the rest when I prep frame for powder coat.

Mounted.

Tossed on the cut down side panel just to see how that is looking. Kind of like the cut down look with the straight fender. May have to work with that idea a little more.

Home depot glassing supplies round 2: $40