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A friend gave me this bicycle because he knew how I liked Sportsters. One in particular, A Bronson Bike

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It would need a front fender as well.

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Getting closer

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here it is next to a real fender. need to cut on the red line and put a lip on the leading edge

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once it's trimmed then you can sand it to make the lines perfect.

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This is the tooling for the lip. I built the power hammer out of an old Riveter,

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Here it's taking shape. The upper die is 3/4" thick marine board

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Just hammer it flat after that or you can leave it open and it is stronger. I wanted it to match.

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A little more buffing and it will look like chrome.

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Now you can see what we are going for.

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Here's the classic Peanut tank shape.

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I had more than 100% penetration so I was able to just go back and fuse the inside

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here it is metal finished. The tank in the background was a failed experiment. It's like a turtle tank.

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Here's the center section laid out and cut out.

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All of the bends were bent or at least started on the brake. A couple had to be finished with a mallet and dolly

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Here are the sides of the Rear fender.

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Here's how I did the offset in the fender. Just space the stepping dies to the correct distance

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run them through. I need to radius the unused edges so they don't mark the metal

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Then slapper and dolly the corners.

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Roll the center of the fender. Over roll it a lot! It will straighten out when you dolly the edges.

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More slapper and dolly work

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Here you can see the planishing hammer marks. I used it to crown the center of the fender, and smooth the slapper blows, as well as smoothing the lines left by the bead roller.

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Weld up the edges and you have the three components for the body work.

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Weld it all together and a little sanding. And you are ready for a test fit. All the pieces are .050 Alumium. 5052 H4 and I didn't anneal it. Just worked it as supplied.

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Here's a pic of the Front fender and the Fake Oil Tank and Fake Battery Cover. All are polished aluminum

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More Parts, Sissy Bar and Air cleaner cover

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Close up of the Air Cleaner cover. E-Wheel Free hand hammer form and welded around teh center of the roll

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Finished. No filler any where

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No kids will ever ride it....it's MINE!!!!!