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I got two sets of the fluted fenders (somehow Theresa thought she had to order one set per wheel?) and had lots of fun with the installation. But they are secure and don't rattle at all, but I'd still love to hear your secret technique, Kevin.
My poor, long-suffering Robust has now gone through several nearly complete rebuilds, including this "French" makeover for spring. Cottered cranks replaced with a Sugino RD2 with a modest 42 t ring; Velo-Orange fluted aluminum fenders; Soma Oxford bars with traditional shellacked cloth tape finished with twine and with cork bar-ends. Now the Vetta saddle and rack just long wrong. . .
Damn, I just typed a long response then it disappeared. Here's my second go around:
I quieted the fenders by wrapping the fender stay in waxxed string at the point where they are next to the fender lip. I also wrapped a figure-8 of string around the nut that attaches the fender stays to the fender (am i explaining that right?). I sealed the deal by melting bee's wax over the string. The fenders are now super quiet, it's amazing.
If you move the rack up to the front, you could use it as an attachment point to stabilize the front fender. By mounting the rack to the fender eyelets on teh bottom of the fork it should drop the rack closer to the fender and you could easily drill the fender and mount it to the rack in a number of different ways...
I have a blackburn rack similar to yours and my fenders just squeezed in there. I didn't have to drill anything, but i had to significantly bend the fenders to fit. I think it worked out fine, see below:
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