Home made fiberglass fenders

It can be done but by the time you spend all the time and money for everything to do it you would be better off just buying a set. If you still want to do it make the mold out of fiberglass. You'll have to bondo/ beat the old fenders till they are pefect (the mold will transfer any imperfections and make it look like crap. You'll also need the spray release (kinda like saranwrap in a can) I belive it's possible to just use ALOT of past wax on the surface instead...it'll be slick enough to seperate (I'd use the spray) Then after all the you have to come up with reinforcing (don't want it to fly into a million peices on the highway after all that!
I'm not saying don't do it but if you're going to plan on making more of them and sell some of them to make it worth your while.
Adam