Step 1: Stuff you'll need
Plastic sheet, I bought 2 chopping mats at the dollar store for 1.50 $ and that's the biggest expend of the project. It looks like PETG but I'm still not sure about this. The important thing to look for is the ability of folding the plastic without breaking it (polymer toughness). I was looking for a black plastic but I still didn't find anything available in small quantity in stores, that's why I decided to go for these transparent chopping mats.
Metal bracket used to attach a bike rack.
2X Bolts and nuts ready to fit on a bike rack.
- 2X Washers.
Step 2: Unbend the metal bracket
2 - Bend your metal piece in a similar radius of your wheel. Think about the offset and make it a little bigger.
Step 3: Print the template
Step 4: Cut the shape
2 - Fix your chopping mat on your template and the cutting mat.
3 - Using an Exacto, cut the main shape by following the exterior line
4 - Cut the 4 little triangles as shown on the picture
Step 5: Mark and fold
2 - On the side of a table, fold the plastic by following the marks. You can do this at first and then start to put more pressure by folding it in your hands.
3 - Finish the folding as shown on the picture.
Step 6: Punch holes
2 - Mark your plastic shape with you template.
3 - Punch holes on your plastic shape.
Step 7: First assembly
2 - With a nail, punch a last hole at the end of the metal bracket.
3 - Fix the second bolt. This step will prevent the fender from moving and making any noise.
Step 8: Final result
You may need to make some adjustment. Tweak it a little bit to get the perfect alignment. You can also modify the template to create your own design.
This tail fender will protect yourself and your followers !
Optional : this project can be achieve using a laser cutting machine.
Please share your pictures.