Custom Flat Fenders.. - JKowners.com : Jeep Wrangler JK Forum
 
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post #1 of 23 Old 03-03-2013, 03:30 PM Thread Starter
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Custom Flat Fenders..

Well it took me nearly 10hrs but I have everything done aside from the final painting.
I apologize for the blurriness of some of the photos, it's hard to tell when my phone is focusing properly.

I started by removing the stock fenders, a 10mm socket will take out the 5 bolts and 1 nut. I just broke the single plastic rivet in the front of the fenders off with a screwdriver.


With the fenders off I used some poster board to make a a template. In hindsight cardboard would have been better as it's more rigid. I ended up cutting it down more from where it is in this picture in order for the mount plate to sit about the ridge on the quarter panel.


Cut off the fender support tab and primed the bare metal. In hindsight I should have kept the tab and added a tapped tab in the fender to bolt to.


Traced out the template on to 3/16 plate.


Plasma cut, cleaned and punched mounting plates. To get the holes in the correct position in used a center punch and poked through the poster board while it was held up to the JK.



Time to bend some tube! One slight error on the calculations for my 2nd bend but overall it worked out successfully.


3 out of 4 bends done. Just the last 90 to do.


Clamped together to ensure equal fit up.


Test fit on the JK to ensure all the angles are correct before welding.


Frame portion welded, time for another poster board template.


Fit the sheet metal to the tube frame while bolted to the JK.


I cut down the stock inner fender which will do for now, it doesn't provide great coverage at the back but it's satisfactory.


Welded tube fender is primed and ready to go.


Modified inner fender is re-installed using 4 of the original bolts, the original nut and a zip tie at the back.


Completed fenders, just need to paint them now but I was a bit tired after all the fab work so that will be done tomorrow if the weather cooperates.
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post #2 of 23 Old 03-03-2013, 03:36 PM
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Re: Custom Flat Fenders..

Nice work!

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post #3 of 23 Old 03-03-2013, 04:00 PM
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Outstanding!
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post #4 of 23 Old 03-03-2013, 04:05 PM
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Nice job.... whatcha selling them for and when?
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post #5 of 23 Old 03-03-2013, 04:27 PM
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Excellent first post! Nice job!

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post #6 of 23 Old 03-03-2013, 04:53 PM
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Nice job


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post #7 of 23 Old 03-03-2013, 09:07 PM Thread Starter
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Thanks guys!

Here is the final picture after paint. Just need to install the marker lights when they come in. Then it's time to work on the rear which should be more straightforward.
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post #8 of 23 Old 03-03-2013, 09:10 PM
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Re: Custom Flat Fenders..

The rears are harder than they look but can't wait to see pics. Once again, looks great!

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post #9 of 23 Old 03-04-2013, 04:40 AM
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Very nice.

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post #10 of 23 Old 03-04-2013, 04:50 AM
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Nice!

Any extra support on those flares?

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post #11 of 23 Old 03-04-2013, 11:54 AM Thread Starter
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Nice!

Any extra support on those flares?
Not yet but a few people on my local board suggested it so I will see what I can make.
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post #12 of 23 Old 03-04-2013, 12:29 PM
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nice work!

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post #13 of 23 Old 03-08-2013, 07:31 PM
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Very nice. Like the idea. Looking forward to seeing the rears.

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post #14 of 23 Old 03-21-2013, 03:10 PM
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Awesome work!

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post #15 of 23 Old 03-23-2013, 03:18 AM
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That is some really nice work. I wish I had that kind of talent

its all about the crawl ratio.
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post #16 of 23 Old 03-23-2013, 04:58 AM
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Custom Flat Fenders..

Looks great. I just finished building mine as well. They were a pain in the ass, but I'm real happy.


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post #17 of 23 Old 03-29-2013, 09:54 PM Thread Starter
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That's what I wish I did on the rear. This way was a PITA but it will do for now. Just needed to get something done prior to my lift install next week.

nd the rear is done, tried something a little different and did tabs instead of a mounting plate. Wouldn't recommend it, stupid JK designers had to go and make everything rounded so it's hard to match the profile perfectly without the plate to hold the sheet metal. Nevertheless they will do the job!

All stripped down, there are 5 plastic rivets to remove in order to remove the inner and outer fender. One of the rivets on the passenger side holds a diff breather so make sure you remember to re-attach that when you put the inner fender back in.


Bend 1 and 2 on the first piece, the 2nd bend on the 2nd piece sucked because the first bend impacted the bender if I put it in the way I had done my calculations so I had to figure the measurements out from the opposite end.


4/5 bends done! Don't have a picture of the completed tube but I'm sure you can imagine how it looks.


Made a template for the 1/8" top piece and sheered them to size. Used a zipcut for the radius.


Ran the two top pieces through the rolls and got them fairly close, a bessey clamp works nicely to get the profile perfect.


Test fit, looks alright.



My forklift hanger for painting, works great.


Best invention ever, nutserts make life easy.


Cut down the inner fender and re-installed.


Tires look small now with such a large opening, new rubber? Ok I got a bit bored while waiting for the paint to dry.


And done. Definitely going to have to trim the rock rails and pinch seam when I do my lift.
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post #18 of 23 Old 03-31-2013, 01:26 AM
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Nice fab work

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post #19 of 23 Old 03-31-2013, 04:22 AM
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Awesome work on all of them
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post #20 of 23 Old 03-31-2013, 04:46 AM
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Without a solid mounting plate on the rears, I would have concerns as to the strength of these and their tendency to bend the body.

Look great. They are a ton of work. I had over 40 hours of fab time into mine.
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post #21 of 23 Old 04-01-2013, 12:50 PM Thread Starter
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Quote:
Originally Posted by Ringer View Post
Without a solid mounting plate on the rears, I would have concerns as to the strength of these and their tendency to bend the body.

Look great. They are a ton of work. I had over 40 hours of fab time into mine.
Yeah I thought about that as I was doing them but I needed at least a temporary solution in order to get my lift and tires on. I only spent 10hrs on the front and 8 on the rear. The nice thing about the tabs is that it will be really easy to cut off and mount to corner guards when I get around to it
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post #22 of 23 Old 04-09-2013, 02:57 AM
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Looks good guys. Wish I had the know how to do stuff like this.
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post #23 of 23 Old 06-06-2013, 01:33 PM
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good job. looks like how I chose to do a set a while back.
https://www.jkowners.com/forum/showthread.php?t=3313

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