I wanted to make a small and simple brat style rear fender for my T250J. The bike came with a shortened front fender which was in a good enough condition to use as blank.
![](https://2.bp.blogspot.com/-WimT-xZoG_8/Ve3mU6xz2zI/AAAAAAAAARA/IuafZxYdix8/s320/%25281%2529%2BSuzuki%2BT250J%2Betulokasuoja.jpg) |
Suzuki T250J front fender. |
I started by drilling out all small rivets which hold the two pieces of the fender together. I also made the rivet holes bigger by drilling them. I decided to use M6 screws so I used a 6,5 mm drill bit. I then traced an arc to the fender with a paperboard template.
![](https://3.bp.blogspot.com/-QlmHcBm9WLE/Ve3mWtLExMI/AAAAAAAAARM/stDiSkcmk7M/s320/%25283%2529%2BEtulokasuojan%2Bleikkauksen%2Baariviivat.jpg) |
A paperboard template helped to trace an arc to the fender. |
I used a battery-powered angle grinder made by Makita with 1 mm thick cutting disc to cut the arc. Once that was done I removed burrs with a sanding machine.
![](https://1.bp.blogspot.com/-479C3MZd5C0/Ve3mXYmUnnI/AAAAAAAAARc/iLKdIzq2D_0/s320/%25284%2529%2BEtulokasuojan%2Bleikkaus.jpg) |
Cut fender, a battery-powered Makita angle grinder
and a sanding machine. |
Next step was to make proper brackets to hold the fender in place. I decided to use 2 mm aluminium sheet as a material. I used M6x16 socket head cap screws, washers and M6 nyloc nuts to hold the brackets on the fender. Two M8x45 hexagon head screws hold the upper brackets and a M8x20 the right lower bracket on the frame.
![](https://4.bp.blogspot.com/-1j8GVCMA_Es/Ve3mXoCRYnI/AAAAAAAAARU/smgF7zi7nfo/s320/%25285%2529%2BKiinnikkeet.jpg) |
Upper and lower brackets and fasteners made out of
2 mm aluminium sheet. |
![](https://3.bp.blogspot.com/-MBlkbFF9Rok/Ve3mXqgrdsI/AAAAAAAAARY/swh_f7kuByo/s320/%25286%2529%2BYlakiinnikkeen%2Bmitat.jpg) |
Measurements for upper brackets. |
![](https://1.bp.blogspot.com/-IRC2YuMJ6y8/Ve3mYEEoBsI/AAAAAAAAARg/qxamQnvhNYA/s320/%25287%2529%2BOikean%2Balakiinnikkeen%2Bmitat.jpg) |
Measurements for right lower bracket. |
![](https://1.bp.blogspot.com/-SmX2CxYXlbI/Ve3mZGpVmtI/AAAAAAAAARw/OZ06e7xkW1I/s320/%25288%2529%2BBrat%2Bstyle%2Btakalokasuoja.jpg) |
Brat style fender ready to be mounted to my T250J. |
The bike came with an unused Michelin 3.25-18 59S M45 E2 tire so I decided to use one as a front tire also. I bought a Michelin 3.00-18 52S M45 E2 tire from my local motorcycle parts dealer Euro Motor Center.
Old tires were in a pretty bad condition. Front tire was a factory installed Inoue 3.00-18. Rear tire was a pain in the ass to remove as it was dried and cracked and wouldn't like to bend over the rim. Motion Pro tire irons helped a lot to remove those tires.
![](https://4.bp.blogspot.com/-FXvBs8_-L20/Ve3mwACnJSI/AAAAAAAAASE/j2msqECOVFA/s320/%25281%2529%2BMichelin%2BM45%2Brenkaat.jpg) |
Michelin 3.00-18 52S M45 E2 front tyre and 3.25-18 59S rear tyre |
![](https://4.bp.blogspot.com/-GC2eDuH2wLM/Ve3mUwu8GxI/AAAAAAAAAQ4/3rM7STm6Bmw/s320/%252811%2529%2BBrat%2Bstyle%2Btakalokasuoja.jpg) |
Side view with new tyres and fenders. |