"Those are beautiful. How thin are the wood strips before lamination? Is this a cold lamination--meaning no steam bending? How well have the fenders retained their shape over time? Have you had any other durability issues--finish problems or bleaching from the sun? And what kind of wood did you use?"
Thanks! Finding the wood strips was actually one of the hardest parts of the process until I realized the term to search for was "thin lumber". At any rate, I used three layers of 1/8" wood. The light wood is soft maple and the dark strip is mahogany. I built the bending form out of three sections of MDF cut to shape and glued together and then I simply cold laminated them using regular wood glue and holding them around the form with two band clamps. After a day of allowing the glue to set, the wood only sprang back slightly and it has retained the shape ever since. Once I had both fenders in rough form, I cut them to size with a reciprocating saw (a band saw would have been much better, but alas, I don't have one...) and applied a layer of shellac followed by a layer of polyurethane. The fact that the wood had sprung back slightly actually worked out pretty well, since they were fairly easy to re-tension with the fender stays. I haven't had them on long enough to know how they will do with the sun and extended exposure to water, but they worked great the first time I rode home in the rain and I figure that if they wear out, I'll just build some more!
Last edited by dcbrewer; 03-10-12 at 08:06 AM.
Reason: Forgot to include the original post