holycaveman

Maybe this has been posted already?

I needed about an inch more clearance in the front for my 32's with a 2.5 in lift. But I like the look of a stock xj so I did not want to lose the flares.

So here is how you remove an 1 1/4 to 1 1/5 of your front fenders and reuse the stock flares.

First remove the flare and re install the flare mounts. Hopefully all the bolts wont break. You have to flare mounts per side.

Flare removed, mounts on.


Next you want to drill 6 1/4 inch holes about 1/2 above the existing studs.
Three holes in each mount and make sure you go all the way through the fender. Notice the fender support tab hanging down. Make sure you drill this hole directly above the existing stud so you can reuse the support tab. I got the bolt hole just a little low on this but its fine.





Once you get all the holes drilled. you can begin to cut. You will be cutting up to 1 1/2 in of metal clear through the fender and the flare mount. I cut right above the existing studs, gives you 1 1/4 in more clearance. Once you cut half of one flare mount off throw in a new bolt to keep it in place. I used standard bolts with lock nuts.






Once you have cut the excess fender off. Make sure you grind the area smooth. Otherwise the sharp edges may just get you. Install new bolts in new holes with lock nuts loosely and mount fender flare back in place. It seems even more sturdy now than it was.

Picture of uncut flare mounted on.



After I cut an inch and a half off of the flare.




I cut the fenders with a standard 4" grinder with cut off wheel. Same with the flares. You can sand the flares for a better finish. I removed the plastic mud guards underneath. I may re install them when I have more time.

Nothing special. But it looks factory still unless you looked under the fender. And 1 1/4 inches was enough to keep my tire lugs from caving in my fender! Which it did once, thats why I had to do this mod.

Some pictures from today. Can not even tell they are cut in my opinion.

diego94

thanks for posting this iv been turning it round in my head for a wile.. the fenders are part of the vehicle thats very visible to people im afraid of making a hackjob, and iv seen very well cut flares turn into looking like hackjobs with a single dent.

in this link (final pargraph) this guy put rear wrangler flares onto his chero, they have a differnet look to them but at a quick glance you dont even notice them. i thought those flares where another good opption to add to this.

http://www.fourwheeler.com/featuredv...e/viewall.html

ChileRedBateman

nice job, I like it... thought about doing that, but got my bigger tires before my lift so i went the TJ flare route, still need to make adjustments but they are on for now
Stock:

TJ Flares:

greenxj21

Thanks for the link! Exactly what I was looking for!

djlarroc

Nice! gona do the same! love the clean stock look.