I was after a different retro look for my nightster and had thought about putting a full length fender on the rear. So grabbed a early sportster fender on ebay. I did not do may reach and found once I got it home it was 30mm thinner than the later sportster fenders.

I decided to go ahead anyway. 

Reshape the tail light area.

Patch the holes.

Mark out the cut.

Screwed some timber to fender to stop it going out of shape.

Cut into two.

Add 30mm strip to widen fender.

Mark out and trim to fit new bike.

Thats where it at.

I've got a lot of cleaning up of welds to do yet. then to decide how to finish the fender off.

One possibility.

Not shore how to finish it off. Have to come up with a few different ideas, see how we go.  Do a test fit to bike next week end.

Did not get much done this weekend. A bit of the clean up and tacked on the bottom piece. I will try to do test fit through the week.

 So got a little more done on the fender this week end. Out side is all about done. Just some cleaning up on the inside still to do.

The small addition on the back edge is small and sutile 2" tail.

Not completely happy with the overall finish. I could just bog it up and rub it back. But I think as a side project I'm going to make a English wheel and roll the bumps out of it.

I'll try and get the test fit done soon.

I have a couple of other thing I'm thinking of doing as well. See how we go.

You could try heat shrinking the stretched steel and shaping it with a hammer and dolly?  Then hit it with a body file to identify any further low spots and tap up and file flat. Easier than constructing an english wheel.

 Yea. Had a bit of a go at it. Long way to go though. Fender has a bit of a twist in it. Still think english wheel is the way to go to get it right. Until then I'll keep tapping at it. Just going to take longer to get it to where I'm happy with it.

Bl@@dy computer

Any I'm not much of a pannel beater.