Cruzin Illusion

On April 27th I originally posted on another website my intentions to start a build project that I have been thinking about doing for a year:
Well I decided to pull the trigger on soon XJ tube fenders. I am gathering all the material I will need to complete my project. The rears will incorporate quarter guards with built in taillight boxes and the flares. The fronts will be built around a front fender guard that will include a fender flare to it. I was going to start the build this weekend, but some of the parts I needed to start were damaged in shipping and I am working on getting a replacement. I have wanted to do this project for a year but had other projects to finish first. I got a lot of inspiration from Brandons flares which pushed this project towards the top of my list. It was nice to see something simular to what I wanted to build and see it hold up to some actual use in Moab. I will keep you all posted.
By May 8th I had received all the materials I was waiting for and started my build:
Well here is an update on where the Jeep sits. I have installed and modified the rear quarter guards. I had to fabricate and add the front portion (dog leg) to both sides. I did this so it will be a true bolt on quarter guard with tube fenders. If you also notice the taillight boxes are part of the quarter guard also.
On the front fenders I have got the fender guards installed and started to trim the frenders to match.
Here are some pics:

Cruzin Illusion

The rear quarter guards are made by THOR4x4 and I am adding onto them with the permission of the owner, which I have talked to quit afew times. He built a set of tube fenders for the rear of his and sent me pictures of what he did so I could get some ideas. Sometimes it is just easier to start with someone elses part and work from there rather than reinventing the wheel.
The fronts came from Slickrock gear but I have had to modify them because they did not fit very well. If I could do it over again I would have made my own fronts. I had to go back and form the fronts to match the curve of the fender because of the fit. It will take a little work to get the finish right on these.
On May 13th I posted up some updated pictures of the build:
Here are some updated pictures:

Cruzin Illusion

I bent the tubes out of 1.5" x .120 D.O.M. It was tough to get the two bend on the rear portion of the rear fenders right along with the front two bends on the front fenders. Notice there is no kinkin of the tube in those area's.

Cruzin Illusion

On may 18th I posted:
have the templates built for the metal skins and am in the process of making the skins. I do have the left side tacked up. Here are some updated pictures. Terry they should be ready to start paint prep soon. Let me know when you have time.

Cruzin Illusion

I tacked welded the inner seem from the bottom. I figure I will just keep rotating around the vehicle to allow for cooling so as to not build up to much heat and warp the sheet metal. I figure we could run a very very small amount of filler to give it a very small transition. They fit very tight against the 3/16" body panel. I also figured it would be easy to grind the welds down on the outer sides and it should give it a nice transition into the tube.
Here are a few outside in the sun.

Cruzin Illusion

I am in the process of finish welding them up and grinding them so there are no seems. My goal is to have no welds showing. They will be very clean looking and not rough.




Not to bad for welding these up side down in the wheel well:



Then they will be preped for paint and the paint scheme will match what I had previous. Orange on the body and Silver on the flares and below the lower body line.

Cruzin Illusion

At this time they are at a friends (87xjco) body shop being final preped for paint. I am hoping by sometime mid next week we can have them ready to shoot. I will keep everyone posted on the progress through this thread. If you have any questions feel free to ask.
Here a few of them being preped for paint:

Here is picture of smoothing out the seam with All Metal:

We used seam filler on the lower side to keep water from catching in the radius portion between the tube and the sheetmetal fender portion. I have heard a lot of TJ guys end up with rust in those areas and I Terry is trying to prevent that.

Cruzin Illusion

It has been a while but I thought I would share a few updated pictures. Here are some pictures of them in primer and with the silver paint on them. The orange and clear are being painted today. I am hoping that I will install them Monday or Tuesday. I want to thank Terry 87xjco and Jamie for the help on getting these preped and painted.

Cruzin Illusion

The paint is done and they came out awesome:
Thanks to Terry 87xjco and Jamie for the help on getting them finished up. Terry is a bodyshop manager and does awesome work.

Cruzin Illusion

Here is the finished product:

Cruzin Illusion