The carbon fibre front fender, on the bike I bought, was damaged.  I ordered a new one, to fit a Monster 1100S but when I fitted it found that it scrapped against the brake discs (see photos below).  Has anybody else come across this?  Comparing it to the old one there is a subtle difference in the curvature of the side portions.  If the vendor I bought it from is unable to find one the right shape can anybody recommend somewhere to get the right one - with a matching weave to the original carbon fibre?  The bit I am having problems with is hard to see clearly in most photos of the fenders I have seen.

Original (left) vs New (right):

The new one in the pic looks good quality so get a DREMEL...

Geoff...

The quality is great.  It exactly matches the original in everything but shape.  I did wonder about  having it cut (I wouldn't trust myself to get it symmetrical), especially as it will be a major hassle to send it back to the USA from Australia.  How easy would it be to cut?  I'm also worried that cutting it would leave a raw edge, at the moment there is a nice bevel to the edge.  Would I just lacquer over the cut piece?

The carbon I've cut has not left a raw edge, much to my surprise.

Masking tape, draw nice lines on it (doesn't have to be symmetrical, just similar), cut 1mm from the line, file and sand. No lacquer required.

Result like this:

What did you cut it with?  I'm guessing a dremel, which I don't have.  Would a small hacksaw work?  Or I have a multitool:
.

Probaly anything that won't compromise the line you draw 

It's more about the file/sand work on the last mm.

Maybe I'll have a try on the old, broken, one. I'm waiting to hear from the vendor but don't expect a reply for a few days. Probably best to not massacre the new one if returning it is still an option!

Have a go at the old one - my guess is that you'll be surprised how easy it is to work on carbon.

People regularly advice against inhaling carbon fiber dust, so good venting (outside?) and a mask is in order

Good luck!

I wouldn't recommend that big multi cutter for precise cuts. I destroyed a perfectly good fender like that. Then again you may not be nearly the hack I am. 😝 Those things are just not intended for precision imo. Are there Harbor Freights in AU? Their cheap version of the Dremel (rotary multi tool) works great and it's like ten bucks.

  To insure semitry make a cardboard template of the curve you want and trace it on both sides.
If you buy a rotary tool you will probably find many uses for it in the future.

Masking tape and very carefully cut with a fine tooth saw, when you've got the approx profile a fine wet & dry paper will finish it off with nice clean lines, I always put alittle washing up liquid in the water to help lub the paper...

But please don't inhale the carbon dust...

As stopintime posts you can get a real pro finish it just takes time...

Geoff...

I'll head to Bunnings and buy a Dremel and some sand-paper.  I already have a face mask, but thanks for the warning.  Practice run on the old one first!

Quote from: StephenC on April 18, 2014, 03:08:55 PM
  Practice run on the old one first!

A very wise decision!

Job done!

Dremel bought - it will be useful for lots of jobs so I'll call it an investment.
Practice run on the old fender - easy as.
Shape masked with tape and then tape moved to the new one.
Cut to roughly the right shape and then sanded to the line.
Finished with some wet and dry - you couldn't tell it didn't come that way.

Thanks to all those who advised.

Nice one Stephen...

We'll make a ducati owner out of you...

Geoff...