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.
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| 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.
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| 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.
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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.
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Upper and lower brackets and fasteners made out of
2 mm aluminium sheet. |
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| Measurements for upper brackets. |
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| Measurements for right lower bracket. |
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| 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.
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| Michelin 3.00-18 52S M45 E2 front tyre and 3.25-18 59S rear tyre |
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| Side view with new tyres and fenders. |
