
Camper fenders are an essential accessory to protect your vehicle from the elements. If you're looking to make your own wooden camper fenders, there are a few methods you can try. One approach is to use a mould and laminate veneer strips onto it with epoxy. You can also try steaming or soaking the wood to soften the fibres before bending it to the desired shape. Additionally, you can cut and shape plywood and reinforce it with fibreglass and paint. Whichever method you choose, making your own wooden camper fenders can be a rewarding project that adds a unique touch to your vehicle.
What You'll Learn
Soften the wood fibres with steam or water
Softening the wood fibres with steam or water is a crucial step in the process of making wooden camper fenders. This technique allows you to bend the wood without it tearing, splitting, or breaking apart.
Wood is composed of fibres and lignins, which are responsible for its rigidity. By introducing moisture and heat to the wood, you can temporarily soften the lignins, making the wood pliable and easy to bend. This process can be achieved through steaming or soaking the wood in boiling water.
If you choose to steam the wood, place the wood pieces in a hot, steamy, and humid chamber. The steam will loosen the wood fibres, and the water molecules will penetrate the fibre cells, making them saturated and flexible. Keep in mind that you'll need to bend the wood quickly after removing it from the chamber, as delaying may cause the wood to crack or break.
On the other hand, soaking the wood in boiling water is a popular method that effectively softens the wood without altering its shape. Fill a pot with enough water to submerge your wood and heat it to a boiling temperature. Carefully place the wood inside and let the process begin. Larger wood pieces will require more time to soften. Remember to exercise caution when handling boiling water to avoid any accidents.
Additionally, pre-soaking the wood in cold water before steaming or boiling can be beneficial. This allows the wood to absorb moisture, which will enhance the softening process. You can also add fabric softener to the pre-soaking water to further soften the wood fibres.
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Bend the wood with a strap and pulley
Bending wood with a strap and pulley is a great way to form wooden fenders for your camper. This traditional method of manipulating wood will give your camper a unique, handcrafted look. Here's a step-by-step guide to help you get started:
Materials and Preparation:
First, gather your materials. You will need a steam generator, plywood to build a steam chamber, medium-density fiberboard (MDF) for your bending form, wood for your fenders, a strap, a pulley, clamps, and any necessary hardware (such as screws, bolts, and washers). Choose a wood species like ash, oak, cherry, or walnut, which can be bent by softening their lignin with heat. While air-dried lumber is typically preferred for steam bending, kiln-dried wood can also be used if steamed for a longer period.
Building the Steam Chamber:
Build a steam chamber to fit the size of your fender pieces. You can use plywood or even PVC pipe for this. Drill holes for support dowels to suspend the wood inside the chamber, ensuring even heat distribution. Assemble the box with screws and attach legs to provide space for the steam generator underneath. Drill holes for thermometers to monitor the internal temperature, which should be maintained at a constant 220 degrees Fahrenheit.
Creating the Bending Form:
The bending form will determine the shape of your fenders. Cut the desired shape using a plunge router and a circle-cutting jig for curved fenders. For complex shapes, you may need to use a combination of techniques, such as routing and hand carving. Once the form is cut, trace the outline on another piece of MDF, cut it out, and glue the two pieces together for added strength. Drill holes around the circumference of the form to accommodate the clamps needed for bending the wood. Attach the form securely to an MDF base using glue and screws.
Bending Process:
Cut your wood to the desired thickness for your fenders, typically between 3 and 4 mm. Prepare your backing strap by cutting it to the appropriate length and drilling holes to match the anchor holes in the wood. Steam your wood for an appropriate duration, typically one hour per inch of thickness for air-dried lumber or twice as long for kiln-dried lumber. Quickly remove the wood from the steam chamber and place it on the bending form. With the help of an assistant, pull the wood around the form and tighten clamps as you go to hold it in place. Leave the wood in the form for at least 12 hours to set its shape.
Finishing Touches:
Once your fenders have taken their shape, you can profile them further using a router table to cut rabbets, round over edges, or create other decorative details. Apply your chosen stain and finish to protect the wood and enhance its appearance. Install your handcrafted wooden fenders on your camper, following standard procedures for fender installation, and enjoy your unique creation!
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Cut the wood to the right dimensions
When cutting the wood to the right dimensions, there are a few key things to keep in mind.
First, you'll want to choose the right type of wood. Look for a flat bar with a thickness of no more than 1/4" for the front fender and 1/4" to 3/4" for the rear fender. Make sure the wood fibres are thin and parallel to the length of the bar.
Next, you'll need to determine the length of the fenders. The front fender will typically be around 1 meter long, while the rear fender will be longer, around 1.5 meters. Cut the wood to the appropriate lengths, using a sharp saw to ensure clean cuts.
After cutting the wood to the right length, you'll need to create a curve in the wood to fit the shape of your wheel. To do this, you can use a bending jig or a strap with a lever and pulley. A simple bending jig can be created using a 26" city bike wheel with a rim wide enough to hold the wood profile. Clamp the wood to the jig and allow it to dry completely before removing it.
Once the wood has dried and taken on the curved shape, you can cut the extremities of the profiles to the desired length. The rear fender can be cut to keep one end with a lower curve, which can be used to connect it to the centre of the bike frame.
Finally, use a belt sander to round off the top edge of the fender along its entire length. Smooth the corners and any rough edges by hand with fine-grained sandpaper to ensure a sleek finish.
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Smooth the corners with a belt sander
Once you've cut your wood to the right dimensions, it's time to smooth out the corners with a belt sander. This is an important step to ensure your fenders are comfortable to handle and install.
First, you'll want to set up your belt sander with the appropriate grit for the wood you're using. If you're working with softwood, start with a lower grit, around 80, and gradually work your way up to a finer grit, like 120 or 150. For hardwood, you can start with a higher grit, such as 120, and then move up to an even finer grit for a smoother finish.
When you're ready, start the belt sander and gently apply pressure as you move it along the corners of the wood. Take your time and work slowly to ensure you don't remove too much material or create uneven spots. It's important to maintain a consistent angle and pressure as you sand to achieve a uniform finish.
As you work, frequently check the progress to ensure you're getting the desired shape and smoothness. You can do this by running your hand along the corners to feel for any rough spots or irregularities. If you notice any areas that need additional attention, go back over them with the belt sander, being careful not to over-sand any particular area.
Once you're satisfied with the shape and smoothness of the corners, you can move on to the next step of finishing the wood. This might include hand-sanding with a finer grit sandpaper to further smooth the surface and prepare it for staining, painting, or sealing. Remember always to work carefully and wear the appropriate safety gear, including eye and ear protection, when operating power tools like a belt sander.
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Paint the fender with protective paint
Painting your wooden camper fenders with protective paint is an important step to ensure their longevity and maintain their stylish appearance. Here is a detailed guide on how to paint your wooden fenders effectively:
Preparation:
Before you begin painting, it is crucial to prepare the surface of the fenders properly. Use a fine-grit sandpaper to smooth out any imperfections or irregularities on the wood. Sand the fender gently, ensuring you do not damage the veneer or wood fibres. Once you have achieved a smooth surface, remove any dust or debris with a tack cloth or a damp cloth. This step is essential to ensure that the paint adheres evenly and effectively to the wood.
Primer:
After preparing the surface, apply a suitable primer to the fender. The primer will help the paint adhere better and create a more durable finish. Choose a primer designed for use on wood surfaces, and follow the manufacturer's instructions for application. Allow the primer to dry completely before proceeding to the next step.
Painting:
Select a protective paint that is specifically designed for outdoor use and offers protection against the elements, such as boat paint or an exterior-grade paint. You may also consider using a paint with a built-in UV protectant to shield the wood from sun damage. Apply the paint in thin, even coats, following the directions on the paint can. It is generally recommended to apply at least two coats of paint for adequate protection. Allow each coat to dry thoroughly before applying the next.
Finishing:
Once you have applied the final coat of paint, let it dry completely. You may then choose to add a clear top coat or sealant to provide an extra layer of protection and a glossy finish. Again, follow the manufacturer's instructions for application and drying times.
Maintenance:
To ensure the longevity of your wooden fenders, regular maintenance is essential. Clean them frequently, and inspect them for any signs of wear or damage. Depending on the usage and exposure to the elements, you may need to reapply paint or sealant every 6-8 months to keep them looking their best and protect the wood from deterioration.
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Frequently asked questions
Use mold release, wax, packing tape, plastic wrap, or an inner tube wrapped around the mold.
Use a backing strip and a lot of clamps. The basic rule is that the pressure spreads out in a V of 90 degrees, so if your object is 1" thick, the clamps will apply 1.44" of pressure.
3-4mm.
It's positive but not necessary.