make Harley-Davidson fender with a different motive

A body man's shrinking hammer and dolly are used to take care of any high sports in the fender before the body filler is prepped and the fender is prepped for paint.
Bob has been known to recess plates and taillights in the fenders after he widens them.

While we were visiting Bob's shop, he also had a fender he was widening for a customer, so we decided to stick around and watch him do the basic steps of that modification, too. He starts by measuring the fender to find its exact center, marking it and cutting it right down the center in the band saw.
Next, a four-inch-wide strip of sheet metal is marked and cut pretty close to the same length of the fender.



Bob stitch welds the strip between the two sections of fender to keep the heat down to avoid warping the sheet metal. Once the fender cools down, the remaining sections of the seams are welded up.
To give the fender a finished look, the extra section of sheet metal is cut off the back of the fender and all the welds are ground down.

Bob then uses a pneumatic flange to create flanges down both sides of the sheet metal strip.
The strip is then clamped into place on half of the fender. Notice that Bob didn't butt the edge of the flange up against the cut edge of the fender. This is so he'll have a little valley to run the weld in and when it is ground smooth, he'll only be knocking the top off the weld. this will leave plenty of the weld between the fender and the filler to hold everything together.