Join Date: Sep 2010
Location: Bristol, UK
Bikes: Royal Enfield Revelation, Dawes Kingpin
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I make my own wooden fenders. The technique is simple. Glue 2 sheets of 1.5mm balsa together and clamp it to a curved mold before it sets. Then glue a layer of wood veneer to the top and clamp again. Cut to size and fashion brackets out of Brass strip, using 4mm garden/fencing galvanised wire for stays. Use several layers of yacht varnish to make them watertight and shiney.
I tend to use Epoxy based glue, an earlier set using outdoor wood glue had issues with the layers coming apart where they flexed.
My latest set are for my current project bike a Royal Enfield Revelation and use walnut veneer and the balsa has been stained with walnut wood stain.
I'm thinking I should maybe go into business, total cost to make a set if less than a tenner.
If you're wondering about the strength of balsa, I had a crash on a bike equipped with a set and the rear of the front mudguard took the force of the landing and was undamaged. My 1st set however I made the mistake of not putting the bracket at the very end of the mudguard and kept getting it trapped in doors causing the veneer to split.
Kingpin with balsa mudguards:
Last edited by Russcoles11; 12-30-11 at 11:22 AM.