Help finishing front fender mod

Well I finally got the nerve to do the front fender mod this weekend. I went somewhat conservative in case I needed to take a second cut. I'm pretty happy with how it came out. I could use some suggestions on smoothing out the edges though. It looks pretty good, but is there a way to make the edge look almost as nice as the factory edge? I cut the fender with a small hacksaw, then ran a file over the edges to smooth them, next ran a sander over it, then some fine sandpaper by hand, and then a pass with the dremmel with fine sandpaper. It came out pretty smooth, yet I still have a few "hairs" showing on the edges. I decided to stop there, so I didn't mess it up, and check with you guys on suggestions. Here's a pic...

You could try using a heat gun to lightly melt the fuzzy stuff so it is smooth.

sswrx wrote:

You could try using a heat gun to lightly melt the fuzzy stuff so it is smooth.

I may try something like that. I still have the cut off piece, so I could practice on that first.

Dig it!

Looks nice! i'll probably do this mod as well on my bike

Use a lighter to burn those fine hairs off for finished edge.

Those little fine hairs should get off with a smooth file. After sanding with fine sandpaper (300 grit), try to polish the fender edge with some drill polish pads. Let's see how it turns out

It may be worth a shot to try using some cardboard to finish sanding it off. I've used it for PVC pipe before, worked surprisingly well. That said, I'm not sure how well it will work with the material of the fender. It is essentially a high grit paper.

EDIT: Just realized how old this thread is. Whoops!

I just finished the mod and i'm quite happy with the result. Looks WAY better than original fender IMO. It's an easy mod if you take the time to cut it it properly. I used a smooth file to remove the plastic residue and 100, 150, then 220 sandpaper. The edge is now smooth.

First cut

100 grit sanding, need a little bit more

Final