donato

how should i cut my fenders. i have a 90 xj. and with what. it has a 4.5 with 32s

96Cherokee113

For the front, I just followed the body line above the mounting holes. I used a cut-off wheel, but there are many ways. You could use a sawzall, dremel with a cutting disc, airsaw, grinder with cutting disc, or if your brave you could try a jigsaw with a metal blade. For the rear, you can't actually cut them because it's two pieces of metal spot welded together. If you cut them, then you weaken the unibody and there's a huge gap that needs to be sealed up. You have to cut slots vertically between the spot welds and end slightly before the body line. Then you bend those with pliers and hammer them flat. There's plenty of great threads around here about trimming fenders. I'll see if I can find a full walk through.

Edit: Here's a write up that should help you out http://www.cardomain.com/ride/3016241/9

ckysodkorn_xj

did mine with a sawzall xD

MASTERS

cut off all extra metal...



then cut up to the trim line, fold over

1995XJ_Sport

I did the cut and fold method for the front and the back..

CRoading

@ 1995XJ_Sport
Nicely done... Your fenders are trimmed cleanly...
I think the cut and fold method is one of the best ways to cut those flares...

donato

how do you make it so the edges are clean looking. how far up should i cut them? with a 4.5 rubicon express on 32? do i have to fold them or can i just slice it all around once i make the little cuts? or will it be to sharp for the tire to hit em?

ckysodkorn_xj

i used door edge molding to dull mine out.

MASTERS

pull your flares off and you will see a body lip about 2 inches up, just cut about 1.25 inches up, leave yourself about 1-.75 inches left to the body lip, then cut them up and fold them over ! your good to go! take your time, crack a beer and enjoy modifying your xj, if you need more advice lemme know

donato

thank you i apprieciate it!

1995XJ_Sport

I am going to be at my buddies house tomorrow cutting and folding his fenders so i will take pics along the way.

1995XJ_Sport

thank you, it is only the second time I have done it.
Here is my old 94, it is the 1st Jeep i did it on..

donato

ok sounds good.. ill probably try to do mine this weekend

xjmarc

Air saw in the front then smoothed it out with an angle grinder, cut and fold on the rear. Getting ready to cut a bit more out of the front and try to figure out a way to do the rear without building new wheel wells.

donato

is the front sharp along on the edges since you didnt fold them? you just sawed it off how ever much you wanted to? or did you cut it right at the where the angle starts going in?