Most likely due to the fiddling around the larger rear brake noodle, the 3D printed bracket holding the fender to the frame failed:
Hey, it lasted for six years.
Making another one just like the other one, but with a little more clearance for the brake cable fittings, required a few tweaks to the solid model:
It’s slightly less chunky and holds the fender a bit closer to the tire:
The piece over on the left cupping the fender wasn’t broken, so I scuffed up the mating surfaces, applied a layer of JB Plastic Bonder (my new go-to adhesive for printed stuff), clamped it overnight, and it looked OK.
While that was curing, I shortened the screw holding the clamp to the bike frame:
The shop vac nozzle does a great job of collecting all the abrasive dust; highly recommended.
Because I had a dollop of adhesive left over, I applied a 1.8 mm drill (from a set of metric bits I’d been meaning to buy for far too long) to the screw:
And glued a snippet of pretty blue PETG filament in the hole:
As far as I can tell, this will have no effect on the screw’s goodness, but it makes me feel better about crunching it onto the frame.
Installation goes like you’d expect and there’s now enough clearance to keep the brake hardware off the bracket:
I replaced the boot while installing the larger noodle; perhaps I should have trimmed most of it away.
The riding season is upon us!
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