Featherlight Fender
Intro: Featherlight Fender
Designed for commuters and travelers, this fender will help you and your followers to stay clean on the road. There is actually no many product on the market that fits great with bike racks. The one I create take advantage of the bike luggage rack. Using a simple folding trick that I've learn doing some packaging, you can make a light, strong and effective rear mudguard !
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
1 - Use a metal vice to ''unbend'' the metal bracket (which one of these two you find).
2 - Bend your metal piece in a similar radius of your wheel. Think about the offset and make it a little bigger.
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
- Open the pdf file and print it on a 11"X17" sheet or make a collage with 2 8,5"X11" if you can't print big format.
STEP 4: Cut the Shape
1 - Fix your template on a cutting mat (not the chopping mat...)
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
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
1 - Using the back of an Exacto knife, mark the folding line. Don't put too much strength on the blade, you only need to create a little weakness on the plastic.
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.
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
1 - Punch holes on your template.
2 - Mark your plastic shape with you template.
3 - Punch holes on your plastic shape.
2 - Mark your plastic shape with you template.
3 - Punch holes on your plastic shape.
STEP 7: First Assembly
1 - Install the metal bracket on your shaped plastic.
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.
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
Install it on your bike and you're done.
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.
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.
16 Comments
tomboyfun 11 years ago
james123cb 12 years ago
i checked your other projects as well. I like your clean, modern designs.
They are unique, yet simple.
I look forward to your other post.
BtheBike 12 years ago
macrumpton 12 years ago
Julien Thibeault 12 years ago
hanleyjw 12 years ago
Jam the bottle's mouth between the stays, and you have an expedient rear fender.
I used to see riders doing this all the time when I commuted on my bike in London.
P.S. I guess you could probably do this on the front wheel as well, but that seems a bit riskier to me (bottle pops off, jams front wheel, wheeee!... over the handlebars).
Lost Moai 12 years ago
Julien Thibeault 12 years ago
Still looking for any neat solution. Maybe I'll work on a pedal strap / shoe protector instead !
Thanks for all your comments, I appreciate :-)
anode505 12 years ago
TygrFr3d 12 years ago
TSC 12 years ago
DanYHKim 12 years ago
capricorn 12 years ago
Two thumbs up and thank you for sharing :)
Mimikry 12 years ago
thank you!
The Papier Boy 12 years ago
Julien Thibeault 12 years ago