> > > 2. When I tighten the stays to the dropouts, it over straightens the tail > and it winds up twisting the other way. Weird. > > This is caused because the fender and stays are not stress relieved (pre-bent). They are not assuming the final shape you want them to before they are bolted up. By bolting, you are forcing a conformation change that creates tensions that change the conformations elsewhere along the system. You need to pre-bend (stress relieve) not only the fender but also the stays before you clamp/bolt them to the bike. Did you bend the stays such that where they slide into the R-clips at the dropouts, they are parallel with the center line of the bike (i.e., parallel with the face of the dropout eyelet)? You literally need to create a kink in the stay near the dropout to accomplish this. Because if you don't pre-bend them to be parallel, the R-clamp will force a parallel conformation, causing stress transfer along the stay to the fender, and causing all sorts of weird alignment changes.
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