In my earlier post regarding the post accident updates I plan for my 2008 Bonneville, I mentioned that I planned to bob the front fender. In this post I share the process of how I went about doing that.


There was minimal damage to my front fender.

2008 Bonneville Front Fender Bob

As noted in my earlier post, I am upgrading my front brakes with a Brembo 4-piston and floating rotor kit from New Bonneville. This kit requires that the fender not have the stock OEM lower fender stay.


NOTE: For installation on a Bonneville, the lower fender stay must be removed to accommodate the new bracket/caliper.

So, I did some quick Photoshop magic to help me visualize where I wanted to go with this project.  I decided upon something not as short as a Thruxton, but short enough to lose the stays. I believe the 4 mounting bolts that remain will be enough to hold the fender in place.


Photoshop visualization of a bobbed front fender.

Step 1

Cut off one end of the fender to use as a tracing guide.


I used a coping saw to cut off the front top end of the OEM plastic fender, just in front of the chrome stay mounting holes.

Step 2

Use the cut off end to trace where you want to cut (bob) the fender.


I decided to position and trace the curve just behind the chrome stay mounting holes.


Here is the traced off front or top of the fender, just behind the mounting holes.


Here I’ve traced of the curve for the bottom end, again just behind the mounting holes.

Step 3

Use a cutting tool to do your rough cuts. It’s plastic so a hand coping saw would work. I used a power grinder.


I used an electric grinder/cutter purchased from Harbor Freight Tools to do my rough cuts.


Close up of rough cuts, and extra pieces.

Step 4

Mask off the curved traced lines for a better visual guide while finish grinding, filing and sanding the edges to perfection.


I used green painters masking tape to mask off the traced line to give me a better visual guide while doing my final sanding/grinding to finish.


The other end masked off.

Step 5 – January 26, 2014 Update

Today I used my bench top grinder to do the final shaping of the rough cut plastic fender, getting as close to the taped guide line as possible.


Bench top grinder being used to shape the rough cut fender edges


Plastic fender edges ground close to guide tape.

Once I had the top and bottom ends pretty close, I removed the tape and hand sanded the edges for smoothness and consistency.


Hand sanding the plastic fender edges


Hand sanding the entire fender in prep for paint.


Hand sanding the under side of the fender as well.

 STEP 6 – Priming & Painting

This past weekend, March 8-9, I applied my first coat of black Plasti Dip spray to the underside of the front fender. After another coat or two, I will apply coats to the outside.


Inside or under side of front fender with one coat of Plasti Dip – Black


Front fender recoating completed with Plasti Dip