I ride my 400EX mostly in the sand and I was wondering what the best way to cut down my front fenders would be? Also how do you match each fender, should I measure from the outside and make marks? How do I make the edges smooth so it doesn't look terrible? Thanks!

 

When i put 27" on my es i had to trim the frount corner all i used was a tin snips and a fine file to finish them off. Looks great to me.

 

On my 300ex I use to have, I put masking tape over the part I was cutting off measured it and looked at it from different angles to see if it looked right. Then I used a new utility knife/blade and cut along the tape. It sliced nicely, then I used my sanding tool on my dremel tool to smooth it out. It looked good.

Later,
Steve Thompson <a>[b]99 Bigfoot Scrambler500[/size]</a>

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[This message has been edited by myscrambler (edited 01-12-2000).]

 

when i cut my fenders, i taped it off and used a jig saw with the finest blade they make and i had my buddy hold them while i cut, sanded them down with 400grit and it looks factory cut now...to make em the same on each side, i drew my curves and lines on cardboard and used it as a stensil and then i drew it with a washable marker on the fenders then i taped them off along the line its quite simple

 

I would (if you have a dremal tool) get the all urpose cuter. These blades are GREAT, you can find them at Sears. You can plung them in, and cut anything in any direction. I have used it to cut through other plastics, and it gos through almost efforlessly the tape is a good idea, if you want the exact same curves on each fender, draw it out on contact paper, cut it out put it facing backward on another sheet, cut it out. Now you have two mirror images, peel the back off, stick on the fenders and use that line to cut along. Hope this helps

Bruce L. Hall
99 Sport 400

 

I have a 2000 400ex and I work with plastic all the time. Here is what I did. Take a jigsaw and use a metal cutting blade. Keep the rpms low so it cuts, not melts the plastic! Now, what I did was... The bottom of a jigsaw usually has a rectangle bottom. I lined up the outside of the fender with the outside of the rectangle and followed the fender. This takes about 1 to 1.5 inches off of the fender. I did it twice because I didn't want full blown race fenders. If you are careful, it will be perfect. After you get it cut the way you want, you can take a belt sander with 120 grit to smooth out and round the edges. Then take 200 and then 400 grit sandpaper and hand sand the edges. Ends up being perfect. If you are really ****, take a heat gun or torch to the edges to polish them and smooth the edges even finer. Looks like factory.