Fender Trimming Advice

[TimmyTXJ]

Happy New Year everyone!
I noticed while moving the Jeep the other day that my wheels are rubbing when I turn and go over any kind of bump. I kinda figured I'd have this issue and was planning to trim the fenders. I want to make clearance but I also want to be able to put fender flares on in the future (can't afford them now). I'm wondering if anyone can suggest how I can trim the fenders to fit either napier flares or bushwacker flares without actually having the flares in hand?

Thanks!

[NW99XJ]

I have to admit, cutting the body up had me pretty nervous back when I did mine....
So I wanted to make sure I did it right.
Here's how it all went down.
Following the natural lines (very carefully) of the bends in the fender just above the holes where the flare mounts are, the metal was trimmed.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1406.jpg

After the trim was done, I took the angle grinder to the edge to knock down any burrs, and to help even out any imperfections in the cut.
Then I took a long bastard file and really straightened any sways in the cut out.
After I was satisfied with the finish of the cut, it was time to tape things off and prep for paint.
I decided to go 1.5" out from the cut edge for my tape line.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1412.jpg

Once taped, I used some fine grit sand paper to rough up the surface to allow the paint (bed coating) to adhere better.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1413.jpg

After the surface was roughed, I dusted it off with a clean rag, then cleaned it with some alcohol.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1414.jpg

After that, the whole area was masked off, I used some paper I had laying around from when I last moved
(the stuff that's used to wrap up glasses and plates with - news paper would work just as well.)
The tire & wheel was masked off using a old tire bag from America's Tire.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1415.jpg

The product used to seal everything up was Duplicolor Bedliner.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1405.jpg

All coated:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1416.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1417.jpg

My cuts didn't turn out dead-nuts perfect.... but they are pretty dang good.
The finished results are pretty good, and if I decide to mod and relocate the flares, It'll look even better.
All finished:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1418.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1419.jpg[/QUOTE]

How it sits now:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG411.jpg (http://s1104.photobucket.com/user/jbchill1/media/IMG411.jpg.html)

Cutting your like this will definitely give you more room,
but not so much that you loos mounting surface for the aftermarket flares that you have planned.
In fact you may find that you'll end up trimming more,
...but this will get you started and give you the clearance you need for now.

[NW99XJ]

The rears are a little different.... I decided to go all out and do the rear quarter-cut-n-fold.
I highly recommend this mod, but it's a DAUNTING task, and you need a full day (if you've never done it before) to make sure it's done right.

I had read what must've been a few dozen (literally) threads on this procedure.
The thread I came back to time and time again was from paraleyes from jeepforum.com and his thread:
"Cut And Fold Rear Lower Quarter Panels - The Right Way!"
http://www.jeepforum.com/forum/f11/cut-fold-rear-lower-quarter-panels-right-way-1007865/
It seemed to be one of the most comprehensive write ups out there, and had a fair number of pics to go with it.
(still not enough though for my liking)
>
With all that and even seeing a few in person I STILL didnt feel 100% prepared (or ready) to start cutting in the Jeep in the way that is required to do this. Honestly - It seems like a simple enough procedure in concept, but in all actuality, it was one of the more difficult mods I've ever done. It didn't help much that I was on a deadline, working late at night, and had a wheeling trip in the morning.
What I should have done was take those who offered up on their offer to help, and driven my happy ass up there to get more heads and hands on this - call it what you will, i decided to go it alone.
Without any more excuses to throw around, I started in on it.
Passenger side was first. I backed it into the garage and the rear wheel came off (for more working room)
http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold001.jpg

The rear bumper came off, and I was ready (as I would ever be) to start in on the real work.
http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold002.jpg

FOUR FRICKING HOURS Later....
THREE FRICKING Cut Off Wheels,
TWO FRICKING different metal blade swaps in the jig saw,
and ONE MAJOR PAIN IN MY ARSE, (main reason for no pics of the procedure) I was done......
With ONE side.
http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold005.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold003.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold006.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold004.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/rearcut-n-fold007.jpg

It's not perfect, I was tired, worn out, and A little high from all the fumes.... But I'm glad I did it, and I'm more or less happy with the results. My plan is to extend the rear bumper along the side similar to what paraleyes did in his write up but with a few differences. I'll tie into the frame, and may even have a small tube flare out that will double as a step (for when loading the roof rack) This will give me great armor protection for the rear quarter, and will strengthen the rear end as a whole.

[XJ Wheeler]

What i would do is look over the instructions to both just to be on the safe side.

Both of these are pdf form btw.

Bushwackers

http://www.bushwacker.com/sites/default/files/product-instructions/10912_r11_2.pdf

Napiers

http://www.napierprecisionproducts.com/media/V2%20Quick%20Install%20Guide.pdf

Sent via messenger pigeon - i talk, he types.

[ekaybe]

You did a really good job. Most people just wing it and make it look like they cut it with a chain saw

[TimmyTXJ]

Damn Josh, great job! Thanks for the pics!

[NW99XJ]

No Prob.... glad to help.

[jimmixj]

Nice job Josh!

[NW99XJ]

Thanks guys,
If I were to do this all over again, there's a couple of things I would do differently.
One would be to not use a jig-saw... although this works, and provided decent enough results, if you were to view it all up close, you can see some imperfections, and a few slightly wavy cuts. Instead I would use a reciprocating air saw, or body saw.
(ONE OF THESE)
http://www.homedepot.com/catalog/productImages/300/38/388051d2-2a8e-46f9-89c2-db14c0169122_300.jpg

I would also consider cutting and folding the fronts like how the rears were done.
This would retain a little more rigidity to the fender as a whole.
Not necessary, but would be an improvement over what I currently have going on.
The rear quarter cut and fold was just plain and simply a pain in the ass.... mostly because I had to use a jig saw.... If I would have used the body saw, things probably would have gone a little more smoothly. I also thing going at it with some cut off wheels would probably have made quick work of some of the thicker metal as well.
On the actual fender side of things in the rear, I would have drawn out a stop line, giving me a more solid and uniform plane in which to end my cuts. I also would have done more cuts. This would have served to make a more even body line when things were all said and done. As it is now, it's a bit rough when looking at it up close.
I have also used something like a windshield sealing compound vs. the fiberglass/bondo (kitty-hair) filler compound I used. This would have been a little easier to work with and finish. I used what I did because I have used it on other projects in the past, and knew it's characteristics. This made the finish work a lot harder and not as forgiving, but it was familiar territory.

[XJ Wheeler]

Thanks guys,
If I were to do this all over again, there's a couple of things I would do differently.
One would be to not use a jig-saw... although this works, and provided decent enough results, if you were to view it all up close, you can see some imperfections, and a few slightly wavy cuts. Instead I would use a reciprocating air saw, or body saw.
(ONE OF THESE)
http://www.homedepot.com/catalog/productImages/300/38/388051d2-2a8e-46f9-89c2-db14c0169122_300.jpg

I would also consider cutting and folding the fronts like how the rears were done.
This would retain a little more rigidity to the fender as a whole.
Not necessary, but would be an improvement over what I currently have going on.
The rear quarter cut and fold was just plain and simply a pain in the ass.... mostly because I had to use a jig saw.... If I would have used the body saw, things probably would have gone a little more smoothly. I also thing going at it with some cut off wheels would probably have made quick work of some of the thicker metal as well.
On the actual fender side of things in the rear, I would have drawn out a stop line, giving me a more solid and uniform plane in which to end my cuts. I also would have done more cuts. This would have served to make a more even body line when things were all said and done. As it is now, it's a bit rough when looking at it up close.
I have also used something like a windshield sealing compound vs. the fiberglass/bondo (kitty-hair) filler compound I used. This would have been a little easier to work with and finish. I used what I did because I have used it on other projects in the past, and knew it's characteristics. This made the finish work a lot harder and not as forgiving, but it was familiar territory.

A 3" cut off wheel worked great for doing my rears. I used a dremel for the front and it took forever! So i don't recommend that. But the cut off wheel allows great control, although curves are a little tricky.

Timmy... Here's my front fender trim from my build thread. Ignore the flare part, unless you want to remount your stock ones too.


"Just a little off the sides"

Finished 04/2010

This ones also kinda a "How-to" for others that may want to do it like this.

For a while after getting my lift and 31s i knew i need to trim the front fenders and just put it off. I was surprised that i even needed to trim with that much lift but it just flexed too much. I could have just bumpstopped it, just didn't want to limit it that much.

Anyway, my process is more complicated than most as i felt the fender was too weak once i trimmed off the lip. Lots of pics and description.

Stock
http://i1108.photobucket.com/albums/h401/xj-wheeler/cimg9950-1-1.jpg

Flares removed
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG9955-1.jpg

I then cut off about 1 1/2 inches. I cut off all of the lip, basically i cut at the first bend. I also cut small 1/4" slits in the rounded portions of the fenders to allow easy bending.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG9963-1.jpg

Next i bent over about a 1/4" lip to add some strength back into the fender. This will chip the paint where the metal is bent.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG9973-1.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG9966.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG9970.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0534.jpg

To add more strength i made some braces that would bolt up to the inside of the fenders. I used 1" x 1/8" flat steel. Sorry i don't have pics of them by themselves, just of them mounted.
http://i1108.photobucket.com/albums/h401/xj-wheeler/2011-06-02184219-1.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/2012-01-27172557-1.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/2012-01-27172349-1.jpg

I wanted to keep the fender braces in the front for now so i cut it as much as i could and still get a bolt in to connect them.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0535.jpg

Also i cut enough off in the back that i lost one of the fenders mounting spots, so i drilled another further back.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0536.jpg

I wanted to keep the stock top brace as well so i cut the excess off and re-drilled the mounting hole.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0541.jpg

Now for the flare. I wanted to keep the stock flares for coverage, but wanted to cut them for clearance and to add a custom touch. I also chose to move them up about 1 1/4" as i now had no mounting holes. I started out by cutting 1" off the outside lip up to the edge. Then cut the front bottom off to line up with the bumper. Cut the rear bottom as it use to tuck under the fender but now can't(red line). I also had to trim the flare to clear my side cladding (whatever its called)(the blue line). Plus i had to make the curve of the flare match the curve of the fender because of moving them up (green line). Also because i moved them up i now had a gap at the body line. So i cut up some of the old flare pieces that i had already cut off and made some pieces to follow the lines of the flare. Not the easiest thing to do. I epoxy'd them on once i was happy with the shape. Then i cut off some of the mounting surface cause it would have stuck down below the fender, leaving approximately 1". Then drilled some mounting holes, 10 to be exact. Sorry i don't have pics of just the flares (other than the gap filler piece) but you can tell most of it by the finished pics below.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0584.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/p20110825-055109.jpg

Now i needed to drill the flares mounting holes in the fenders plus a couple more for the braces. Once i got all those lined up i painted the portion of the fender where the paint got chipped and the new holes were drilled. Although i didn't want to go past where the flare was in case the paint didn't match (it didn't match). I also painted the inside of the fenders cause i messed up the paint knocking on it. I chose to put silicone on the bent over lip to keep trash out of the valley.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG0530.jpg

Then i painted the flares after smoothing them. Hint: use Adhesion Promoter on the flare before painting, it will help prevent cracking.

Bolted it all up once the paint dried, and love the new clearance and look. Although at full stuff i still can't turn without hitting the flares and maybe the fenders.
http://i1108.photobucket.com/albums/h401/xj-wheeler/2011-06-01174817.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/2011-06-02184019.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/2011-06-02184041.jpg

While flexing
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG2952-1-1.jpg
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG2951-1-1.jpg

See, this is at full stuff and the wheel turned straight ahead.
http://i1108.photobucket.com/albums/h401/xj-wheeler/CIMG2930-1.jpg








Sent via messenger pigeon - i talk, he types.

[XJ Wheeler]

Just thought of another tip. Since yours is an older style like mine i suggest cutting off the bottom of the front fender that is in front of the tire, about even with the bottom of the grille. Most aftermarket flares call for it anyway and it gives you a good bit more clearance for turning while flexing. Still need to finish mine off like that.


Sent via messenger pigeon - i talk, he types.

[OldFaurt]

I have to admit, cutting the body up had me pretty nervous back when I did mine....
So I wanted to make sure I did it right.
Here's how it all went down.
Following the natural lines (very carefully) of the bends in the fender just above the holes where the flare mounts are, the metal was trimmed.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1406.jpg

After the trim was done, I took the angle grinder to the edge to knock down any burrs, and to help even out any imperfections in the cut.
Then I took a long bastard file and really straightened any sways in the cut out.
After I was satisfied with the finish of the cut, it was time to tape things off and prep for paint.
I decided to go 1.5" out from the cut edge for my tape line.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1412.jpg

Once taped, I used some fine grit sand paper to rough up the surface to allow the paint (bed coating) to adhere better.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1413.jpg

After the surface was roughed, I dusted it off with a clean rag, then cleaned it with some alcohol.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1414.jpg

After that, the whole area was masked off, I used some paper I had laying around from when I last moved
(the stuff that's used to wrap up glasses and plates with - news paper would work just as well.)
The tire & wheel was masked off using a old tire bag from America's Tire.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1415.jpg

The product used to seal everything up was Duplicolor Bedliner.
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1405.jpg

All coated:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1416.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1417.jpg

My cuts didn't turn out dead-nuts perfect.... but they are pretty dang good.
The finished results are pretty good, and if I decide to mod and relocate the flares, It'll look even better.
All finished:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1418.jpg

http://i1104.photobucket.com/albums/h328/jbchill1/IMG_1419.jpg

How it sits now:
http://i1104.photobucket.com/albums/h328/jbchill1/IMG411.jpg (http://s1104.photobucket.com/user/jbchill1/media/IMG411.jpg.html)

Cutting your like this will definitely give you more room,
but not so much that you loos mounting surface for the aftermarket flares that you have planned.
In fact you may find that you'll end up trimming more,
...but this will get you started and give you the clearance you need for now.[/QUOTE]

Gee, the guy who had my jeep before me went nuts, he just taped over the door handles and locks!http://i1186.photobucket.com/albums/z367/weirdshots/MyJeep_sm.jpg