DIY Network

'48 Indian Motorcycle Restoration: Frame Repair and Painting Fender skirts and other parts are fabricated as the restoration of the 1948 Indian chief continues. From "Classic Rides" episode DCLR-305

The dingy frame on our 1948 Indian Chief motorcycle looks rough, but not for long. Antique motorcycle expert Chris Matthews, and Classic Rides host Craig Reynolds begin restoring the frame and metal parts on the bike.

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	Craig cuts the sheet metal for creating the new fender.
	Chris grinds the sheet metal as he forms the fender skirt.

Project Overview

Chris and Craig start with redesigning the metal fenders by adding classic metal skirts. All the metal is then cleaned and prepped for paint. Next, Craig and Chris get out of the garage and head over to the paint booth to clean, prep, sand, prime, and paint the fender and tanks. They then head back to the shop and finish up with painting the frame.

The basic steps as seen in this episode of Classic Rides, as well as the tools and materials used, are summarized below.

Tools and materials:

Original Indian motorcycle fender
MIG welder
pneumatic cutting shear
hand tin cutter
belt sander
4x4 1/16" steel plating
pliers
C-clamps
body hammer and metal forming bag
gloss black chassis paint
wire brushes
metal and plastic scrapers
orbital sander
various grits of sandpaper
degreaser
safety equipment and eye protection
fire extinguisher

Note: This is a summary of steps included in the automotive restoration procedures shown in this episode of Classic Rides. These are general guidelines for restoration procedures on this particular make and model of motorcycle, and for the level of restoration selected for this project. There may be variations in procedures depending model, condition of vehicle, level of restoration undertaken and the types of replacement parts or upgrade kits selected. Always follow proper safety precautions, and read and follow manufacturer's guidelines, diagrams and safety notices that come with any replacement parts or kit that you select.

Safety Alert: Always wear eye protection and follow proper safety precautions when working with power tools or pneumatic tools.

Safety Alert: Always follow appropriate safety precautions when welding, including wearing of protective clothing, welder's helmet and eye protection.

	Chris custom fashions the new fenders with flared fender skirts.

Fabricating the New Fender Skirt

The original fenders on our Indian were beyond repair, so they needed to be replaced. Chris t had an original Indian replacement fender, but the skirts were missing, so new ones will have to be fabricated.

Steps:

• Using an existing template, lay out the skirt pattern on 1/16th in steel plate. If no template is available, one can be made by tracing an existing fender with skirt.

• Once the pattern is traced onto the metal, secure it to a bench with C-clamps.

• Using the pneumatic shear, cut along the line. Once the skirt pattern has been cut out of the metal, clean the edges up with the belt sander.

• Use the skirt that has just been cut out as a pattern to trace onto the metal for the other side. Repeat the process of cutting it out.

• Once both skirts have been cut out, Chris tack welds them together using the Mig welder so when he does the final cleanup with the belt sander the two sides will be mirror images. With the skirts matching, it's time to make the edge lip.

• Metal fabrication is a skill that takes some time to learn, so it's always better to have a professional do the work, but our work on the fender isn't that complicated so it is something an amateur could try. Using the pliers, make the first bend in the top edge of the skirt. The bend will allow the skirt to flare out.

• Once the first bend is complete, use the pliers to make the next bend. This one will be closer to the edge of the skirt and will allow the face of the skirt to tuck under the fender and it will be to this edge that the attachment weld is applied.

• The bends can then be smoothed using a body hammer.

• Once the skirt has been shaped, clamp it in place on the fender and using the Mig welder, lay down a bead along the edge of the fender skirt.

• Repeat the steps for the opposite side and allow the fender to cool.

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