This is a shortened version of my thread from the folding forum regarding a Dawes Kingpin customisation. I thought others may want to learn from my experiences of making my own wooden mudguards. The idea came from seeing http://www.woodysfenders.com
-Create a mould or form over which to bend your mudguard (I just nicked something the right diameter from work)
-Take 3 lengths of balsa wood 1.5mm thick (length and width greater than you want for finished mudguard) and glue them together.
-Very quickly then clamp these to your form. I used an inner tube lengthwise around the form and wood and just 2 clamps to avoid denting the balsa. I also used masking tape along the edges.
-Leave overnight at least to set.
-Take the Balsa off the form and check for sections not glued adequately, push glue into any cracks using a piece of card and re-clamp to the form with the clamps over the glued sections.
-Leave overnight again.
-Cut cherry laminate to size (for me this was 5cm wide and length measured against another mudguard) and glue this on top of the balsa curve and return to the form overnight.
-Carefully trim excess balsa using some sort of saw or knife using the laminate as your template.
-Place the mudguard in position on the bike and check what fixings will go where. Mark positions and drill any holes needed.
-Varnish the mudguard (marine varnish recommended for weather proofing). Sand down and varnish again until you have a suitably thick layer of varnish.
-Screw on the fittings
-Attach to bike
-Remember you need to do this twice for 2 mudguards. Use the best one for the rear so you can choose the best section of the other for the shorter front mudguard
You can swap the cherry for whatever wood finish you want.
You can try with other woods than balsa but I tried all cherry and found the result very springy
12 sheets of balsa (1.5mm by 10cm 1 meter long cost me about £3
12ft of cherry veneer (1mm by 60cm) cost me £5
Glue used was an exterior pva type £5
Marine varnish £5
Fittings from a busted up old pair of plastic mudguards
Total cost £18
Its worth noting that I was making mudguards for a 20" wheel. Larger wheels may get away with thicker wood as the bend is not as severe.