Felix, I finally got to answering your email...sorry, been busy and things do get temporarily lost in my inbox.....
Most of the fenders you see on those bike shows are spun, then welded together I believe. It is a lot of work to make a fender from scratch, and most of the bike builders on tv should spend more time building parts so they can keep learning. Doesn't pay as well as tv I guess...maybe a few of them will buy my dvd if I'm real nice? They are not all as good at metalshaping as Jesse James is. I still admire the creativity though.
As soon as my arm is back to normal from all the pounding, I'll be finishing up my part of your flares. Here is an album with a little on the technique I used top generate a lot the shape in the bike fender:
http://allshops.org/cgi-bin/community/comm...d=9980191607382John www.ghiaspecialties.com