Today I finally got around to starting on the fenders.  I'm using a composite technique called "fleece" where you stretch some fabric over a wooden form to get a smooth shape or curve.  Fleecing works perfectly for the shape of these fenders.  I used 1/4" MDF to cut the wheel shape and the flare.  The flare is about 2.5". Next I stretched some cotton spandex over the forms ( I hot-glued the wood to the body to hold it in place).  3M 77 spray adhesive holds the fabric to the wood and body.
 Next I stretched some cotton spandex over the forms ( I hot-glued the wood to the body to hold it in place).  3M 77 spray adhesive holds the fabric to the wood and body.
 Here is the fleece with a couple thin coats of epoxy.  The epoxy will give the fleece just enough stiffness to add the layers of composite fabric.  After the Kevlar is molded, I can release it from the fleece and removed the wood forms.
Here is the fleece with a couple thin coats of epoxy.  The epoxy will give the fleece just enough stiffness to add the layers of composite fabric.  After the Kevlar is molded, I can release it from the fleece and removed the wood forms. 
 


 
 
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