Once dry, release the clamps and remove your rough fender from the jig. Using a table saw, cut a smooth, square edge along one side. Then measure, mark, and cut the desired width for your fender. Mine are 1 5/8 inches wide, but it depends on what looks good to you, and the mounting space available on your bike (space between fork and seat stays).
Shaping your fender
Using a rasp, file, or sanding block, smooth your fender’s square edges and shape the ends into a curve. Sand until smooth with a coarse grit sandpaper, such as 80 grit. Repeat with finer 220 grit for a smoother surface.
Sealing your fender
Once your fender is shaped and sanded it’s important to seal it – after all, you now have something on your bike that can rot! Use varnish, paint, or a coat of epoxy to seal your fender and protect it from rain and UV rays. I use a coat of epoxy resin, brushed on to add strength and bring out the fender’s wood grain.
For the second part of this article, see related links.
View more photos by Galen Maynard aka "Dapper Lad Cycles" at www.flickr.com/2kings