On Jun 23, 7:56 pm, MichaelH <mhech...@gmail.com> wrote:
> I noticed some unusual rattling from my rear Honjo fender today, and a
> close inspection revealed a crack at the seat stay bridge attachment.

One tricky thing with installing metal fenders is getting them where
you want them without putting stress on the fender.  Even when you
have the fender a perfect circumferance and the holes drilled in the
perfect locations; tightening of the hardware at the stay ends can
twist the fender and bow the stays.  To correct the bowing stays,
you'll need to bend each side a few inches from the clamp so the stay
moves within the clamp (after loosening) without binding.
Additionally, when tightening the clamp, you need to hold the clamp in
place while tightening, or it will twist the drive side stay upwards
and the other stay downwards, stressing the fender.  This may be the
one advantage of using the daruma-type bolts for stay attachment.

That said, your fender failure may have nothing to do with that at
all.  Fender reinforcements on that section were popular back in the
day, and are currently on JP Weigle's customs:

http://www.flickr.com/photos/49353...@n00/3585634727/

You could probably repair your fender using a similar approach.  Just
be sure to drill a small hole at each end of the crack before doing
so.

John McMurry
Burlington, VT
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