HemiNeko.net Blog

Rupp parts have become rather expensive lately, seems we are one of many Rupp restoration projects. Of the many parts we needed for this restoration is a 1971+ Rupp rear fender. We found a good front fender off eBay but the rear fenders are just too expensive for our budget so we make our own.

We start with a cheap Honda Chibi mini bike fender off eBay (10$). This finder has similar dimensions to what a Rupp fender should have, emphasis on width and angle. The fender was too short, about 4 inches too short. So, we weld some 16 gauge sheet metal on after forming it and cutting it. *Note* notice the missing section at one side of the extension. This was intentional as the Rupp fenders have this tab for clearance.

We also used the front fender (which we found on eBay for a good price (sniped)) for referencing the edge curvature for the rear fender.

We used an old Mity Mite stick welder; it runs on household 110V and is adjustable different rod sizes. We (now) always use Lincoln rods since the alternative, cheap Chinese rods are too hard to work with (which results in poor welds). We should be using something like a MIG welder for sheet metal but cannot afford it. Many say you can’t weld sheet metal with a stick welder, well, when that’s all you can afford then you can make it work…

We grinded the welds down, applied fiberglass body filler for strength then several regular layers of regular Bondo to even things out.

Why do I share this? Well, it would be interesting to me to read about someone else’s experiences in making parts with like this but more so to illustrate the kind of work my dad and I do.  We don’t have the right tools, nothing ever fits the first time, and we can’t afford to do it ‘right’.  But we get the job done to almost professional level (opinion) through creative engineering and taking our time to do it the best we can.  Also, this was my dad’s project, I was working on the frame and tank while he worked on this.