Mark-II Slim-Line fender brackets
The Mark-I Slim-Line fender brackets were a tad flimsy as demonstrated by crash test results. The Mark-II model uses 5/16" fuel line instead of the 1/4" brake line used previously. Here you'll not only see how to make them but how to get the fender exactly how you want it. Don't think for a moment there's any uniformity to CJ sheet metal parts. The fender holes were probably drilled without a template, so careful measuring is the order of the day. Let us begin.
Tape blocks of wood to the tire to support the fender while you fool around.
Once the fender is at the desired height above the tire, tape it in place.
Find something to center the fender between the forks. In this case, paper tags were used.
Carefully measure the distance between the holes for each bracket. The results might surprise you. In this case, they were not uniform.
Mark the tubing accordingly. There are three marks. The end mark is for cutting. The center is for the hole, and the inner mark is for the squeeze.
I used tubing that already had one prepared a few days earlier. The measurements run from the hole centers.
Cut on the cutting mark you just made.
Give each one a good squeeze in a vice using the inner mark for reference. Re-mark the hole locations.
Punch the hole centers.
Drill pilot holes.
Drill the screw holes.
Grind off the square edges and run them through the wire wheel.
Done.This time, I wanted the fender slightly higher than before. I also painted the brackets black instead of the fender color as I like the way this looks on Ross Kowalski's bike and wanted to do the same with mine.