assuming you are okay with it looking like something from the New California Republic you could cut one out of sheet metal
the two tabs at the top would be folded up then wrapped around the forks and held in place with bolts through the holes like hose clamps.
the bottom two taps would be folded down and a bar passed through the holes to secure it to the axle like any other fender.
might be either weak or heavy depending on the gauge of metal used.
[edit]
just thought, you could cut the shape out of some card paper, form it around the bike, then baste it with fibreglass and resin. in theory would be stronger and lighter than metal used this way, also could be sanded and shaped then painted for a better appearance.
the two tabs at the top would be folded up then wrapped around the forks and held in place with bolts through the holes like hose clamps.
the bottom two taps would be folded down and a bar passed through the holes to secure it to the axle like any other fender.
might be either weak or heavy depending on the gauge of metal used.
[edit]
just thought, you could cut the shape out of some card paper, form it around the bike, then baste it with fibreglass and resin. in theory would be stronger and lighter than metal used this way, also could be sanded and shaped then painted for a better appearance.
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