Originally Posted by Bikeguy1
I need to cut part of the fender out to fit my wheels and was wondering if anyone has done it? I dont want to ruin the whole thing.
I know that they are just plastic and am worried if I tried cutting it that it would split or crack or something. I would also like to drill a couple holes in it for mounting it.
Any advice would be appreciated. Thanks
I just mounted a front SKS fender and I had to cut some holes in it to make it fit up into the fork and still give me proper tire clearance. These fenders are not a smooth curve and the fork I was trying to fit has a very narrow smooth curve and would not let the fender seat snugly against the crown. To solve this problem I had to make some oval holes on either side of the fender where it was making contact with the bottom of the fork crown (it's a CF fork). I also had to remove the original hanger (mounted to the top of the fender with two rivets), as it's thickness was also interfering with the fender to tire clearance. I replaced it with the same SKS hanger (called a "brake bridge clip") that they give you for the rear fender. It grips the sides of the fender and costs you no clearance on the top. These hangers should work on any fender and you can get them in four different widths at Harris Cyclery. They are flexible and can easily be bent. See:
-- scroll down and look for "Brake Bridge Clips"
The plastic that these fenders are made of is extremely tough stuff (but still easy to drill). I cut out my holes by first drawing an outline of the ovals I wanted to cut out. Then I drilled small pilot holes. I then used a UniBit to drill the majority of the rest of the whole. UniBits are great for soft materials and sheet metal, as opposed to regular drill bits which stink. To go from the round hole to the ovals, I finished the cutting with the Dremel tool. I then finished the edges with a couple of grades of emery cloth. I also tried cutting with aircraft/tin snips and they worked just fine but were too big to really get into the holes I had cut, so I ended up with the Dremel tool. I could have done the whole thing with the Dremel, but I am sure the UniBit saved me a lot of time. I had to keep fitting the fender to the fork until I got the holes I needed.
Since there are only a few inches of fender that protrude in front of the fork, the holes I cut out did not weaken the fender to any significant extent and the hanger holds up the front just fine.
This exercise gave me a new perspective on what to look for in a bike or fork that you will be installing fenders on. Those huge, wide open spaces under a Rivendell fork look very nice right now ;-)
Good luck with your project !!