Ok, so this is all in my build tread as well, but figured I'd save people some time and put it all in one place.
I am doing a 3" stretch on my two door, so buying tube fenders was not an option. I also am going for low COG, and wanted very high clearance. I settled on 1.25"x.120" wall DOM tubing for the fenders, 14 gauge steel for the tops, 3/16" plate for the front fender backing plates, and PSC corners for the rear.
Fronts:
I started by making a posterboard template, and then transfering to 3/16" plate. I used three pieces of plate, and welded together, rather than buying one big piece.

I used a plasma cutter to cut the backing plates.

The plates were then clamped to the body, and mounting holes drilled and nutserts installed.

My old tubing bender took a crap on me at the beginning of the project, so here is what I picked up. A JD2 model 32 bender with a SWAG hydraulic adapter and a Larin Hydraulic jack. I build the stand for it.

Time for some geometry to figure out the bend angles and tubing gain from bending.

Bending up a front tube

Front fender tacked into place. These are 1.5" narrower than factory.


I added some support tubes and a plate with a stud to catch the factory support.

Fronts all bent up.

Skins were then cut from 14 ga steel, again using the plasma cutter. They were cut larger than needed, and then cut down to size once tack welded on.

The front curve was compound, and took some heat from the torches and body hammers to shape into place. Skins were tacked into place from the inside, the outside was then ground smooth to the tube.

The entire outer edge was welded, then ground smooth. I used a combination of flap wheels, a belt sander, and hand sanding to get them smooth.