Projects: I gotta get this thing FINISHED!

I last wrote about the “Repurposed Bike” on 9/2/11.  To be honest, I haven’t done much on it since then.  It’s time to get it back into action.  (I have the distinct feeling I’m going to need a dedicated commuter this Winter.)  So here goes a bit more.

Fender Improvements:

I’ve already mounted the fenders on this thing, and now I want to make them a bit better.  This is done by fashioning some extended mud flaps.  Adding a flexible flap to the bottom of the fender increases the coverage, and greatly decreases the amount of water and road gunk that is thrown onto the rider.  This project has another advantage.  It’s virtually free.

Start with a one gallon plastic milk jug.

I mark the jug with an indelible marking pen.

Then, using a good stout pair of shears, cut the jug along the lines.

This results in two sections.  These are the raw materials for the mud flaps.

The next step involves drilling the mounting holes in the fenders.  This is done with a drill and a small bit.  Usually the holes will be about an eighth inch in diameter, but make sure they are just big enough to clear the hardware.

What hardware?  Well, you’ll need four screws, eight nuts, and eight washers.  This is small change stuff, readily available at any Ace Hardware Store.

Two holes are drilled in the fender, about one inch above the rear bottom.  Be sure to make them far enough apart so that the flap is well supported.

Final shaping of the flap parts takes place.  Cut and form to the fender.  Removal of the remainder of the jug’s screw top, and the bottom triangular section happens here.  It’s possible to choose the best orientation for the size and shape of the target fender.  Some will take the “corner” quite well.  With others, it’s best to simply cut and shape the flap out of one of the flat sides.

Place a washer on the screw.   Insert the screw through the flap, and then the fender, from the inside.  Drop a second washer over the screw, then two nuts.  The first nut is tightened down, and the second serves as a locknut.

Here’s a finished view of the rear.  The rear is done in a similar fashion.

Note how much more coverage this provides.  It’s nice to have dry feet!