Restoring Cab Fenders on a 1989 Ford 655D Backhoe: Fitment, Fabrication, and Field Ingenuity

The Ford 655D backhoe loader, produced in the late 1980s and early 1990s, remains a dependable workhorse in construction and agricultural fleets. One of the more overlooked components in restoration and maintenance is the cab fender—those curved panels that shield the operator from mud, debris, and tire spray. On older machines like the 1989 655D, sourcing replacement fenders can be a challenge due to discontinued parts, model-specific fitment, and structural wear. This article explores the practical realities of cab fender restoration, including sourcing options, fabrication strategies, and field-tested adaptations.

Terminology Notes

• Cab Fender: A curved metal or composite panel mounted above the rear wheels, protecting the cab and operator from debris.
• ROPS (Roll-Over Protective Structure): A safety frame integrated into the cab, often affecting fender mounting geometry.
• Sheet Metal Gauge: Thickness of metal used in fabrication, typically measured in gauge (e.g., 14-gauge steel).
• Mounting Tabs: Welded or bolted brackets used to secure fenders to the cab frame or ROPS.
• OEM (Original Equipment Manufacturer): Parts made by the original manufacturer, often discontinued for older models.

Challenges in Sourcing Fender Replacements

• OEM fenders for the 655D are no longer in production
• Aftermarket suppliers rarely stock body panels for legacy machines
• Salvage yards may have rusted or damaged fenders with poor fitment
• Cab variations across years and regions affect compatibility
• Mounting points may differ between open ROPS and enclosed cab versions

A contractor in Alberta searched for months before finding a salvage 655D with intact fenders. He had to modify the mounting tabs and drill new holes to match his cab’s bolt pattern.

Fabrication Strategies

When OEM parts are unavailable, custom fabrication becomes the most viable option. Key steps include:

• Template Creation

  • Use cardboard or plywood to trace the curve and dimensions of the original fender
  • Account for tire clearance, cab door swing, and mud flap integration

• Material Selection

  • 14-gauge steel or 1/8" aluminum recommended for durability
  • Galvanized sheet metal offers corrosion resistance
  • Composite panels (e.g., fiberglass) are lighter but harder to shape

• Bending and Shaping

  • Use a slip roll or brake press to form the curve
  • Hammer and dolly techniques for fine shaping
  • Reinforce edges with angle iron or bead rolls to prevent flexing
• Mounting and Finishing
• Weld or bolt mounting tabs to match cab frame geometry
• Prime and paint with rust-resistant coating
• Add rubber edge trim or mud flaps for protection

One operator in Georgia fabricated his own fenders using salvaged trailer wheel wells. He cut and reshaped them with a plasma cutter and mounted them using U-bolts and angle brackets. “They weren’t pretty,” he said, “but they kept the cab clean and the inspector happy.”

Fitment Considerations

• Measure tire diameter and travel arc to avoid rubbing
• Ensure door clearance and visibility are not compromised
• Match fender width to cab profile for aesthetic and functional alignment
• Reinforce mounting points to handle vibration and impact

Field Anecdotes and Adaptations

A township fleet in Wisconsin retrofitted fenders from a Ford 555C onto a 655D by welding extension brackets and trimming the rear edge. The mechanic noted that the curve was close enough, and the bolt pattern only needed minor adjustment.

Another story comes from a farm in Oregon, where a 655D had lost both rear fenders during logging work. The owner built new ones from 55-gallon drum halves, welded to flat stock and painted yellow. “They looked homemade,” he said, “but they lasted five winters.”

Preventive Maintenance Tips

• Inspect fender mounts and welds annually for cracks or rust
• Touch up paint to prevent corrosion, especially in salted environments
• Clean fenders regularly to prevent mud buildup and tire wear
• Add mud flaps or splash guards to extend fender life
• Store machine under cover to reduce UV and moisture damage

Conclusion: Function Over Form

Cab fenders on a 1989 Ford 655D may not be glamorous, but they serve a vital role in operator safety, machine cleanliness, and regulatory compliance. Whether sourced from salvage, fabricated in a shop, or adapted from another model, a well-mounted fender restores both function and pride to a classic backhoe. In the world of legacy iron, ingenuity often replaces inventory—and the results speak for themselves.