Thanks pal!

So I wanted to do the square tube rockers, but to do that I have to take the doors off.
Might as well do a removable door conversion first.
The wires were a bit of a screw around.
First I used butt connectors, and a few of them came out within a few days.
So I soldered and shrink tubed every one.

 

New wheels and tires!!!

15"x10" 3 3/4" B.S.
33"x 12.5 Procomp Mud Terrain (used)

 

Time for a celebration!!

Woah,
Who's she?

 

Back to work.
Time to get rid of these tin rockers and open up these fenders.

 

Cutting.

 

Cut the rockers out up to the door seal.
Cuz of this, I had to trim a few inches off the doors
I've seen a bunch of threads where people did this and used 2"x6" tube.
I went with 3"x6" cuz I thought it looked better.
Still got a bit of work ahead of me. Gotta tie it all in.
Working on my flairs at the same time. One of the more challenging things I've done so far.

 

Just a little trick to get the cut on your doors straight.
I've seen other people have them not match up after.
Cut your rockers out with the front fender on.
Cut the fender inline with your rockers. Then put your doors back on and snap a chalk line.
Cut the body panel side of the door on the jeep. Then take the doors off and cut the rest on the bench or saw hoarse er whatever you got.

 

So I started on the fender flares and did I ever open up a can of worms with this one.
The goal is:
Flat fenders using 1 1/4" square tubing
3/4" x 1/8" flat bar braced against the body tied in with 1/2" square tube and skinned with 18 gauge sheet metal.
Getting started was the hard part. I made about seven templates before I even made my first cut.
I started with the front and cut and curved the flat bar to match the fender's contour.

 

Then on to the rear.

I went through a lot of inspiration juice on this one. I want The rear to match the front.
This ain't easy on XJs cuz you can't just go hacking up the C pillar.
I decided to make a split flair and attach half to the door.

 

Then I started cutting and tying in the 1 1/4 square tube with the 1/2" square tube.

 

Here's my pal that sold me the Jeep.

He's pretty stoaked that it didn't get crushed now.

 

Oh and I keep all my beer boxes.

Great for making templates and for masking.

 

Got the front fenders done ready for paint.

This calls for a tall boy!

 

nice. thinking about doing the same, only with round tube.

 

Cool.

I went with square tube cuz I haven't seen it done before and I wanted to keep this build boxy looking.

Here's the rear. Just rapping it up today.