1) Body filler is applied to the old fender, which will be used as the template. This fender was widened 1 1/2 " from stock to fit wider tires.

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2) Again, this is the old fender. It needs to be pretty straight in order to use as the template.

3) Here, we start shaping the first section of the new fender. This new fender will be made out of 8 sections of flat 19 Gauge AK steel.

4) Here we have the center 4" wide section formed and completely welded in. It takes about 1 hr per ft to complete the welding, grinding and smoothing.

5) We're fabricating the inside section that bolts the fender to the car. This is one of the final fits before welding to the rest of the fender.

6) The panel fits good, now we start the tack welding process. You must do your welds in 1/4" tacks and let cool so you don't warp the metal.

7) The welding and smoothing of the metal is completed.

8) This shows how this part of the inside panel folds over where it will bolt on the car.

9) Here we are working on the top inside section. This part starts off 20" long, 4" wide and flat. Then we bend it on the sheet metal brake. This is so we can get the center body line, that runs forward to back, on the fender. Next we shrink the edges to get the shape of the fender.

10) Here we have shaped the forward inner section. This part was a little different, because the body line stops before it gets to the front of the fender. You can also see that we started building the front outer section.

11) This part was difficult down were it meets the running board. This has a small reverse curve going outwards toward the front. We built an aluminum die, shaped like the running board, and hammered this area forward.

12) Here we are welding the panels together.

13) After grinding and planishing, the welds are invisible.

14) Another angle. These two parts are finished. Check back, to see this fender completed

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