Rear Fender Trimming (Cut and Weld)

Old 09-09-2016, 03:53 PM
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DenimDean's Avatar
Join Date: Jul 2013
Location: St. Joseph, MO
Posts: 1,453
Year: 1994
Model: Cherokee
Engine: 4.0
Default Rear Fender Trimming (Cut and Weld)

For this, you really only need a few things. Welder, angle grinder, hammer, and vice grips.

1. Mark and cut. I cut the outside first, then cut the inner fender. Doing this leaves a lip that you can mark and cut accurately. If you were to just cut through from the outside, it would probably cut the inner fender too far and leave a gap.

2. Clean the lip with a wire wheel and make relief cuts on the wheel well. I ended up doing 5 cuts.

BEFORE YOU CUT!!! There is a wire harness in the fender that needs to be moved. I just set it up on a bolt and made sure my cuts were shallow.

3. Mark and cut the excess. I didn't cut any excess off below the body lines, this leaves you enough metal to fill the gap where it widens up.

4. Next go over the wheel well with a grinder and make sure it doesn't shove your fender out when you push it up. This will help keep it straight when you weld it together. I did have it pull in a bit in some spots, but it's not very noticeable.

5. Weld it up! I used vice grips to hold up the wheel well where I wanted it as I welded. I held it up around 1/8" from where I cut the fender. (Ignore my terrible welds, my welder was acting up for majority of the welding on this side.)

6. Clean it up with a grinder and you're done! (I ended up going back and getting it to look better, but these are the only pictures I have.)

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