Cherokee tube fenders
 

I can't seemed to find after market fender flares that i like. So I decided to build my own tube fenders since now I have most of the tooling. Bare with me as the process goes on:

https://cimg2.ibsrv.net/gimg/www.che...c00cdb451b.jpgStarted off with removing the fenders. Super simple task.https://cimg4.ibsrv.net/gimg/www.che...42eafa2b1d.jpgI picked up some angle iron from Lowe's. This is where i will weld my top tube too. I drilled some holes and bolted them up.
https://cimg8.ibsrv.net/gimg/www.che...1b86f76e19.jpgThe tube im using is 1 3/4 and also 1 1/2. The top tube is 1 3/4 and notched to fit in the corner of the door and windshield. I will cap the inside to keep dirt out.
https://cimg8.ibsrv.net/gimg/www.che...fc6bbd7b5f.jpgNotching the tube. This way made it a little easier
https://cimg2.ibsrv.net/gimg/www.che...02eb3d08de.jpgA little more cutting to the notch to help fit in corner of the door and windshield
https://cimg8.ibsrv.net/gimg/www.che...0a218c49c5.jpgPre fitting to that corner

https://cimg2.ibsrv.net/gimg/www.che...23626db97e.jpgPre fittment
https://cimg8.ibsrv.net/gimg/www.che...1d5fa3f753.jpgTack welded in place
https://cimg5.ibsrv.net/gimg/www.che...d65b0cb582.jpg
https://cimg4.ibsrv.net/gimg/www.che...63d3f8bfe7.jpg
https://cimg6.ibsrv.net/gimg/www.che...818422aef4.jpg
https://cimg8.ibsrv.net/gimg/www.che...ae3e3b4dd8.jpg
other than pre bending some other parts that's it for today

SUbbed to see how these go!

I'll sub in as well. Gotta smooth that front edge for sure but sweet concept so far.

oh yeah definitely!

https://cimg4.ibsrv.net/gimg/www.che...f718613665.jpg1 1/2 tubing notched and bent. This will be going in the door jam area and connect to the unibody frame.
https://cimg7.ibsrv.net/gimg/www.che...c95c42d4e8.jpg
https://cimg8.ibsrv.net/gimg/www.che...33170c4e4c.jpg
https://cimg9.ibsrv.net/gimg/www.che...657c6e7e7d.jpgZip tied to the vehicle to check fitment

https://cimg4.ibsrv.net/gimg/www.che...c4a51a7c21.jpgGetting ready to tack. I placed a block of wood to ensure i had room to open and close the door
https://cimg5.ibsrv.net/gimg/www.che...529414e358.jpgSome flat plate to tie into the frame.

https://cimg8.ibsrv.net/gimg/www.che...5959191132.jpgTacked in place
https://cimg9.ibsrv.net/gimg/www.che...b9813e4c35.jpg

now to start the tubing near the grill

https://cimg2.ibsrv.net/gimg/www.che...bcde7e0adb.jpgSo i dont like how tucked in the tubing was compared to the grill so i came up with a type of spacer.
https://cimg0.ibsrv.net/gimg/www.che...5db61d918f.jpgI cut some tubing in half, drilled a hole and welded a bolt in. These will be mounted in yhe factory holes that the stock fender was bolted to.
https://cimg1.ibsrv.net/gimg/www.che...be170c12a9.jpgIt will look something like this. Tubing will be welded to the mounts/spacers. Just needs a little tweaking to get it where i like.

Newbie mistake #1. Can't notch straight when there is a bend so close to the clamp holding the tube. Had to hand notch this one but so far so good.https://cimg3.ibsrv.net/gimg/www.che...e6ca7c26d3.jpg
https://cimg6.ibsrv.net/gimg/www.che...07e259dcb7.jpg

https://cimg4.ibsrv.net/gimg/www.che...d3662c4823.jpgtacked. Now the tubing that flares it out

you have greatly peaked my interest. i like where these are going!

thanks, I appreciate it!

Flare tube is tacked up and I also added a support. Thats pretty much it for tubing. I will be sheet metaling to close it up when I get a chance to run to my metal supply guys. Than it's just capping all the holes, shaving some edges to keep it sleek, and paint. https://cimg9.ibsrv.net/gimg/www.che...4fb61a69a9.jpg
https://cimg0.ibsrv.net/gimg/www.che...5632b6fee8.jpg
https://cimg4.ibsrv.net/gimg/www.che...084e60845c.jpg
https://cimg6.ibsrv.net/gimg/www.che...e4edb949bc.jpg
https://cimg7.ibsrv.net/gimg/www.che...d912b40593.jpg
https://cimg0.ibsrv.net/gimg/www.che...c0f412321f.jpg

have you checked your uptravel with the tires on and turning lock to lock? looks like they may hit the tubing before they bumpstop out.

So I tested it and yes they do hit at lock before reaching the bump stop BUT at the moment I still have cracked factory bump stomps. I should be getting extended versions soon. I made a measurement between the bump stop mount and the plate. When I get the extended bump stops I'll squeeze by with no rub. :thumbsup:

What about when you go to a bigger tire?

I won't be going bigger. Iv already built a TJ the was off-road based with big tires, 3/4 axles, stretched, fuel cell and towed to the trails but that's a different story. This is a DD weekend warrior. I want the xj to travel across the state's with decent MPGs, trail ride, and come home comfortably on the highway.

This is more of my expedition rig. The stock axles will be able to handle the 33s with no worries.

Ive had good luck with the Daystar extended stops. 32" tires and 4.5" lift were perfect for fenders trimmed up to about where your rails are. if nothing else, they would be a good base so you dont have to add as many hocky pucks to the coil pad. :cheers:

thanks for the recommendation!

its been 5 days.....updates !?:w00t:

Had to leave town for work for a couple weeks but when i get back I'll be finishing it up.

:cheers: Just giving ya crap

are you bending tube yourself, or are you using pre bent pieces? i just don't understand why you would only use one bend in the wheel arch.

I wondered this as well.

Not dissing this at all, but it just looks odd...you're doing a bang up job so far...and I'm guessing you have a bender, as the piece near the door has 2 bends.

If it were me, I would take the time and do, at least, a second bend to even out that angle on the bottom tube. Something that more follows the contour of the wheel well. Even a small amount would even it out, plus would probably solve your issue under compression at lock.

Just some constructive criticism. Please don't take it the wrong way...and, if you've got plans that haven't come to fruition yet, just keep going, sometimes it's hard to visualize if you can't see where the other person's thought process lies.

Either way, more pics, LOL

Digging it for the most part!

I'll agree it looks different and odd at the moment. But that's the point for me. Yes I have my own bender and the reason its has one bend is because everyone does two. I personally did not want to follow the same lines as stock or follow someone else's after market design. Hopefully when i build my front bumper it will go along with the new fenders. If not ill cut them off and redo it. 👍https://cimg8.ibsrv.net/gimg/www.che...e76ca7ba37.jpgHere is my old wrangler, badass but looks like every modified wrangler. Im going for different with this cherokee

Fair enough. Looking forward to updates.

Updates ?