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This is a cute project, that takes a little thought, I had problems making the first set of fenders, I think I can cut through some of the trial and error for you. for material, I used walnut for the body and ash for the fenders.
Ok, first make 3 copys of the plans, keep one to read, one to cut the body with, and one to cut the fenders with.
Trace the fender pattern on a piece of 1X6. Make sure you label the front and back of each fender and also the inside and outside too.

Now cut around the whole outside of the fenders as shown. It should look like a big dog bone. Make sure you don't cut off your labels!
This is where I screwed up the first time. Chuck a 1/2" round over bit in your router table and go around the outside of each fender. This means you may have to route one fender, then flip the thing over and route the other. Depends how you layed it out. I ended up with two right hand fenders!
After you route the fenders, cut the rest of the fenders free. You should have somethin like this.
See my Ride: 1600 Vulcan Crusier
Sand the fenders completly, you won't be able to later. I used a two inch drum sander mounted in my drill press to sand the wheel wells. Hint: Cut a hole in a thin piece of plywood or similar so the sander passes below this new table height. Also if your using 2" wheels, you need to remove a little more stock than the plans show.
I also made a little sanding block to get between the running boards and the fenders. When your satisfied (or sick of sanding) Set it aside and start the body.
Heres a crummy shot of the body in the clamps. Total assembly is 2 3/4" thick. This got kinda heavy, a friend of mine suggested cutting out the window area to lighten it. Use the windows on the pattern to follow for cutting.
Ok, tape your pattern on and start cutting. You can mark the axle locations at this time too.

Yup, thats a big chunk of walnut. Lay the fenders on the body and mark where the fender meets the body. You need to route the top of the body with a 1/4" round over bit and you don't want to route the body where the fenders are. Drill the 9/32" axle holes.
Ok, now finish sanding the body and the fenders and glue them on! Lookin good! Then finish as you like. I cheated and used poly to get mine done quick. It's going in the daycare, so I don't know how long it will last!
I used 2" wooden wheels, I painted the tire part black and then polyed the whole tire and the axle pegs. I never did cut out the windows, looks good, but very heavy for little hands.
 If you want the plans,  Click Here!

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