Have made some good progress on the TW200 over the last couple of weeks. Originally I was going to use a steel black fender and cut and shape to suit. However I wasn't happy with the outer radius as most of these off the shelf fenders that would fit the 7" wheel were flat.
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| Scrap Ply to use for the plug |
I decided to shape my own creating a plug out of plywood to replicate the radius of the wheel. Once that was done I filled the spaces with expanding foam. I probably should have used the two part expanding foam as the builders foam left too many air pockets after being shaped.
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| Nailed into place |
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| Expanding foam to fill the voids |
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| Should have used 2 part expanding foam as there were so many air pockets |
Then I glassed a female mould with 2 layers of woven cloth and a layer of chop strand. Because the foam wasn't perfect I had to spend a bit of time sanding and filling the holes left by the foam.
Next I created the final male mould, this time I used a Vinylester Resin for increased flexibility and strength compared to the Polyester.
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| Vinylester Resin with woven mat |
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| Final result after sanding. Ready for primer and paint |
It came up really well after a trim and a light sand and fits perfectly to the rear tyre and is also super lightweight. Now to fabricate the mounting hardware.
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