Surly LHT, Surly Big Dummy, Surly 1x1, Surly Pugsley, Bike Friday Tikit x 3, Bike Friday NWT, Bow Cycle 24, Santa Cruz Nomad
I've got Planet Bike Cascadias on mt BD with 2.0" XRs. I don't think there is room for 2.35" tires, but you could call Planet Bike and ask - I'm sure this question has come up before.
I was looking for metal fenders myself, but you need a fender 10mm wider than your tire - so for a 2.0" tire [or 50mm] you need 60mm fenders. I wasn't able to find anything I was happy with - although Wald did have some wide enough they were as heavy as a battleship.
For 2.35" tires [or 60mm] you'd be looking for 70mm metal fenders. If you find anything useful for 2.0" or 2.35" tires please post back in this thread and let us know about it.
Vik: What you really want would be the PB Cascadia 29" fenders (not 26"). They are 65mm wide, and the increased radius helps, too. I have actually installed these on a Big Dummy with 2.35" Big Apples, and they look like they were made for it. As for paint, no worries. When I worked for a custom frame shop, we used to paint Silca frame pumps (plastic) and Esge fenders (also plastic) to match the frames, with excellent results. Sand the surface lightly, wipe down with rubbing alcohol, use good paint and allow proper curing; you will not be disappointed.
I know you asked about metal due to paint desire. You know you can paint plastic, right? I have had good luck with the DupliColor for-plastic spray can stuff sold at auto parts places. If anything it is easier to get a good finish and adhesion than when painting metal. Though I haven't tried painting them, my Planet Bike Freddy Fenders (plastic) have done well for me. Just sayin' is all.
Salsa Las Cruces - Specialized S-Works Langster - Seven Sola - Surly Big Dummy - Specialized S-Works Tricross - LeMond Fillmore - Electra Amsterdam - Velorbis Scrap Deluxe - Giant TCR Advanced - Gaulzetti - Cannondale Cyclocross Red - Speedvagen
It's as much about the look and ease of painting as anything. Most non-metal fenders have odd shapes and are not a consistent material. Yes, I could probably use an adhesion promoter and flex agent, but it's just a difficult item to paint.
Even on th cascadias, which are fairly plain, you have non-removeable rivets and the non-removeable black flaps to deal with.
I think that plastic-spray probably works ok, but I'm going to be color-matching the bike (not the factory color), so that's not an option.