Onward and upward with the front brake project. As noted previously, I finally sourced a matching fork slider and caliper, and ordered caliper and master cylinder rebuild kits plus new fork seals. First order of business however was to remove the fender mounts since a proper bobber doesn't need them. I gotta say I bought a mini portable band saw and it has proven to be super useful. That plus a set of 40 grit and 80 grit sanding discs on my angle grinder made short work of this.
Chucked it up in a vice, and yes I know I should never clamp the vice down on the tube, but as it so happens the tube is badly bent (this came from a bike salvage place on eBay) and I don't need it anyway, so I'm good.
The non-brake side fender mount was easy.
The brake side fender mount is a little trickier, as the caliper mount "extends" up to the fender lug so it'll need a little shaping.
Both fender lugs removed, and feeling lighter already.
Now for the really delicate part, grinding the remains down smooth without over-grinding and damaging the slider itself. I started with a 40 grit wheel which cut the aluminum waaaay faster than I expected so I changed to the 80 grit but that was way too slow, so I put the 40 back on and had to ease up on the pressure and be super gentle.
After the heavy sanding was done, I put the 80 grit wheel back on and smoothed it all down. Behold, the finished product!
I could probably smooth this down even further with some hand sanding with higher and higher grit paper, but I am not trying to make a show bike, so I'll roughen up the aluminum/remove any clear coat and give it a coat of flat black and then install post haste. I wouldn't even bother with changing the seal in the other leg but the seals came in pairs and I couldn't sleep at night knowing I had a new seal and fluid in one fork and not both. All told this was probably an hour's worth of work, and I am happy with how it came out.
It's time for Humankind to ditch the imaginary friends of our species' childhood and grow the fuck up.
"Lasse mich deine Seele dem Herrscher der Finsternis opfern"
Let me sacrifice your soul to the ruler of darkness
Always carry a bottle of whiskey when you travel in case of a snakebite. Futhermore, always carry a small snake.