Royce Burnett's Journal

Well, I've been struggling with the best way to fix up the headlight area of this fender ( other than buying a new one of course). There was a few spots rusted thru on top, as well as on the bottom. this wouldn't have been too bad, but the front flange of the fender which is welded to the ring inside the fender was complete crap, as was the ring itself.

After much thinking, I made a couple of front fender bits by bending a piece of sheetmetal about 12 inches long by 1 3/8 wide, bent a 1/2 inch 90 along it, and put it in my shrinker stretcher. First one didn't fit all that well; to meet the fender line it wouldn't need to have a 90 degree bend, at least not all the way along it. Second one I made turned out pretty well. I had joggled the edge before I put it in the shrinker as I wasn't convinced of my butt weld skills. Next was to take the Dremel with the reinforced cutting wheel to the fender, and try to cut a straight edge in the right place.

I also had to make an inner ring as it was pretty well shot in most places and I didn't feel like piecing a bunch of bits in there. Still have to drill holes and make new threaded pieces to mount the headlight in the hole.

Worst of this job is knowing I have the other fender to tackle... should go a little quicker I hope.