Cutting Wheel Radius For Fenders

Nov 23, 2011
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I'm working on making some X fenders, it has been a while. What are some of the options to make the cut so there isn't a lot of gap between the radius of the wheel and the inside radius of the fender?
 
I got a Pinecar hand hacksaw set up with a round file in it. That file is the perfect radius so I used that to rough it out then put 120 grit (what I had) on the tread of the wheel to just smooth it out. Worked well enough. Then put a small rubber band on the wheel to create my gap when gluing my fenders on. Rough but worked... for now.
Thinking a drill press might be first big expense for my new found addition. Bulldog's vids helped me to make that decision.
 
No. I don't plunge the wheel through the balsa like Bulldog shows in his video. I glue the sandpaper on the tread of the wheel. Then grind in radius into the edge of a balsa piece cut to size.

A picture might help ...

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No. I don't plunge the wheel through the balsa like Bulldog shows in his video. I glue the sandpaper on the tread of the wheel. Then grind in radius into the edge of a balsa piece cut to size.

Ohhhh! I feel like a dummy. Knew I was missing something.

Bulldog is a Pro and makes it look easy. I've had pretty good success with his method, but I've twisted hubs, had sandpaper come unglued, etc..

That looks like a good idea worth trying. Thanks brother!
 
I'm a newb in league racing. A forstner bit sounded like the best way to do it, and 1-3/16" is very close to the diameter of a stock wheel. (~1.18 is to small for the 1-1/4" and to big for the 1-1/8" Lowes sells. I bought mine off Amazon. A 1" forstner looks to be very close to the raised Street Stock 4th wheel, but I'm not ready for that build). Bulldog has a fenders video and spacewalker has videos on working with balsa (and CA glue) on YouTube.
For pictures npwdrl forum and facebook has the monthly rundown of cars. From what I saw at Nationals the gaps are extremely small.
 
Maybe I should clarify. ...
Spray adhesive a 30 or 40 grit disc to the elevator bolt. Use the drill press to press it firmly on the sanding disc that Bulldog suggested. Then remove and trim. (could use a belt sander to fine sand it round) then use drill press to make wheel holes, but press softly and clear the paper and dust often or it'll get hot! I use 2" long elevator bolt because it gives me more to chuck and longer plunging range! I've had the same one now forever so it last if you keep clearing the sawdust and don't burn it.
Good luck.