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Make your own rollerski fenders

Sun, Oct  19, 2014 - By Randy Kessler

I've been skiing on the V2 Aero for 2 years now. Love everything about them except...water from the rear wheel during wet conditions comes onto the back of my leg and fills my boots up very quickly.

I asked Len Johnson of Jenex of any fender designs for the rear wheel or know of any aftermarket versions. Unfortunately, Len said that requests for a  rear fender has been very small, almost non-existent.  He said he mentioned to many Aero users that some skiers wanted a fender, but they felt it should be a low priority item. From a cost standpoint, Len said even the simplest injection mold costs about $4000.00 so the return is pretty poor. It's possible an aluminum fender could be designed and tooled for as little as $1,500 and he said when he had some time he might seriously look into it. Len suggested fabricating your own. So until then...

make your own rollers ski fenders

Making Your Own

Here's how I made my own fenders, and these suggestions work for most rollerskis, not just the Aero. I have speed reducers on the front of my rollerskis, so I only made fenders for the rear wheels. If you don't have speed reducers, make fenders for both front and rear - the process is the same:

  • Buy some polypro PP about 3/32 thick.
  • Cut it to size using a hand saw. It cuts easily. I also found the polypro could be cut with a utility knife.
  • Using a heat gun (a hair dryer might work) you can heat and bend it. Notice that I bent a 90 degree angle into the material where it attaches to the rollerski. 
  • Drill two or three holes into your rollerskis and attach the fender with pop-rivets or screws. 

There's one problem you may run into: There might not be enough room between your binding/boot and the rear wheel to mount the fender. Before you buy material, make sure you have the room on your rollerski. If you're buying a new rollerski, have the bindings mounted an extra 3/4" forward.

The polypro sheet I bought was from McMaster-Carr ( Another possibility might be using polycarbonate (Lexan) window material, available in a lot of hardware & building supply retailers. The thickness is probably about right, it's heat formable and fairly tough stuff, but only available in clear.

There might be a plastics distributor on the Internet who caters to hobby & small-order customers, but I didn't find one in the search I just did. Most had bigger minimum orders or didn't carry the polypro sheet.

The results have been worth it: my feet stay much drier!