57flh01.jpg
This is where we start, a very poor rear fender, the best of whats left.
|
57flh02.jpg
Siren hole, cracked, split, torn, a real mess.
There are also tears around the battery strap hold downs.
|
57flh03.jpg
We have remover the rear fender section, and the braces, the owner managed to find a N.O.S. fender flap. Lucky man.
|
57flh04.jpg
This is the roughed in replacement siren patch.
|
57flh05.jpg
We had to remove the inner reinforcement where the U-clamps hold the fender to the frame, straighten the inner brace, and the outside of the fender, Blast it, weld through primer, and re-attach it, we also removed the reinforcement for the fender brace by carefully drilling the spot welds, straightened it and the fender, and re-installed it. There also were Eight saddlebag holes on each side of the fender. These required some shrinking because a panhead fender has a slight roll on each side. There were numerous cracks and tears at the toolbox mount area, and the fender brace areas needing welding and repair. I put a car fender washer behind the toolbox hole to strengthen the area.
|
57flh06.jpg
The repair section welded in, and also another stress crack welded at the chain guard relief.
|
57flh07.jpg
N.O.S. Fender flap
|
57flh08.jpg
After all the welding is complete, a final sand blast before applying filler.
|
57flh09.jpg
The whole fender will receive a skim-coat of filler.
|
57flh10.jpg
Left side of same fender. The fender braces even had holes that needed welding and straightening.
|
57flh11.jpg
Filler work completed, Right side.
|
57flh12.jpg
Filler work completed, Left side.
|
57flh13.jpg
Left Gas tank filler work finished.
|
57flh14.jpg
Right Gas tank being pressure tested. I will put four pounds of air in each tank to find leaks.
|
57flh15.jpg
Under the primer, soapy water bubbled in this corner, after blasting, we found this repair to leak. We had to remove the brass so we could weld the corner up, but there were more holes.
|
57flh16.jpg
This is what we found when we removed the brass. Welding can not be performed over Brass. it ALL needs to be removed.
|
57flh17.jpg
These holes were under a fiberglass patch where the tank emblem goes, also visible is one of several dents in the tank.
|
57flh18.jpg
Two more holes accompanied by a stress crack at the seat T mounting area.
|
57flh19.jpg
Welded and a new emblem mount fabricated.
|
57flh20.jpg
Rear of tank welded, this was the worst hole, inside the tank is obviously thin. We would weld it, grind it, test it, several times, the blast it and touch it up again.
|
57flh21.jpg
The stress crack just kept traveling on this one, each repair was done four or more times before the tank would hold four pounds of pressure. Gas tanks are not pressurized in use, they are vented, feeding fuel by gravity. to hold four pounds of pressure is more than adequate.
|
57flh22.jpg
This is the Left tank pressurized, and being tested with soapy water. it was fine.
|
57flh23.jpg
every joint and every seam passed the test.
|
57flh24.jpg
Left side in good shape. I lightly blasted the insides of both tanks because they were rusty.
|
57flh25.jpg
This is a late model, probably 1972 front fender. We removed a bracket on the left fender mount, relocated the brake tube mount drilling and taping the hole, and welding the old hole. We also welded four holes in the rear of the fender for a late style moulding, and we fit the stainless trim and drilled for it.
|
57flh26.jpg
The front fender is off a Disc Brake front end. It had been hit in the nose, hit in the rear, and someone had put a lot of filler on it without fixing the dents. We fit a 1958 and later moulding to the nose to get the proper shape, and fit a stainless trim to the rear, and properly pushed out the dents. It will receive a skim coat.
|
