I've got some more web space now, so I've put the three PDFs there:
http://www.angib.pwp.blueyonder.co.uk/t ... nder-5.pdf
http://www.angib.pwp.blueyonder.co.uk/t ... nder-6.pdf
http://www.angib.pwp.blueyonder.co.uk/t ... nder-7.pdf
And here are the instructions I sent out when people asked for these drawings:
Here is the template for the fender 47-1/2" long to suit a 15" tyre.
Attached are three PDFs:
- slumber-fender-5 contains the outside profiles for each main slice of the bread and butter section;
- slumber-fender-6 contains the inside profiles for each main slice;
- slumber-fender-7 contains general information and views, the full-size template for the little slices of bread and butter that make up the flare-out at the back of the fender and a nesting plan for the 3/4" slices.
Here's how I think you have to use the templates to cut the outside profiles:
- Print them out and cut, say, the bottom and left margin off each sheet.
- Stick them on a piece of thin ply or masonite. Make sure that every inch of the paper is well glued along the profiles, so that it won't peel off when you are cutting.
- Check that the two check dimensions on the template measure correctly.
- Fit the outside template to your piece of ply and cut the outside profile of slice 11 and drill the four alignment holes. Each cut you make will cut both the slice and the template
- Repeat for slice 12, but only cut as far back as the end of the inset on slices 1 and 10.
- Repeat for slices 1 and 10, cutting the whole of these slices.
- Refit the template to the partly-cut slice 12 and cut the very back end. All this bother is because most of slices 1 and 10 are smaller than slice 12, but not at the back end, where slice 12 is smaller!
- Repeat for slices 13 to 15. Slices 15 and 16 will need to be spaced further apart than the 14-1/2" shown for the 3/4" slices
- Slice 16 is cut the same way, but you can probably get by without drilling the holes in this slice. You can cut both the outside and inside profiles of slice 16 from the outside profile template.
Having cut the outside profiles of all the slices:
- Make up and check the template of inside profiles in the same way.
- Use the four alignment holes to fit the template to slice 15 and cut the inside profile, leaving the bosses on around the alignment holes.
- Repeat for slices 14 to 10 and 1.
Doing it this way means you only need to make up one template for the outside profiles and one template for the inside profiles - each time you cut one slice, the template gets a bit smaller, so you have to be sure to cut the slices in the right order.
Slices 2 to 9 are identical and so it would be worth setting up the template to cut the slices with a router.
The slices are assembled using some 1/4" pins in the alignment holes. I would buy some really long bolts (preferably stainless steel) and wax them before putting them in the holes - this way, once the slices are bonded together you should be able to drive the bolts out, so that you are only cutting wood when you come to remove the bosses around the alignment holes!
Slice 16 can be fitted to the stack without using alignment holes - its bottom lines up with all the other slices and the inside edge of three of the bosses line up with the inside edge of the slice.
Andrew
Posted: Wed Sep 26, 2007 4:44 pm
