JacksXJ

Hi All,
I'm going to install a set of Bushwacker flat fender flares on my 99 XJ and wanted to get opinions on how/what I should do to protect against rust along the cut lines.
My other question is; the install instructions say that your supposed to cut the front section of the wheel well/rim clean off and fold the back end of the well - why wouldn't you just cut the whole thing off?
I'll be doing all four corners.
Lastly, I have a 3 inch lift and currently run 31's - with the fenders installed can I get 33's in there with the right offset and bump stops?
Thank you for your opinions....
Jack

ckysodkorn_xj

the back is "pinched" together with rossette welds thats whats basicly holding the body together so be very careful to cut between these not through these. and with 3 in of lift you can stuff 33's but you may want to concider regearing first.

JacksXJ

I've read that I may have to regear - would the difference be that big going from 31's to 33's? I figured I would try it out first with the stock gears and see how it is.
What should I do to prevent rust where I cut, that will last? Has anyone ever rewelded along the cut, would that work?

NatetheOgre

I am running 33's on my stock gears as well as I have cut the rear fenders. Not the cut and fold. I did have to tack it all back together though, and used expanding foam for some areas as well.

ckysodkorn_xj

running 33s on stock gears is possible i would just be scared of over working the trans and prematurly wearing the gears. for the unfinised cut what i did in the front was i got door edge trim and black spray paint. taped everything up good and sprayed it and then but the molding on because i didnt use flairs.

Slimgoaty

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OEJ

the tranny will eventually have problems if you dont regear with 33s. the aw4 shifts into OD @ 42mph give or take and the rpms drop way down and the tranny will struggle until the rpms come up again.

whith my 33s i put it 3rd around town and dont go into OD until im @ or over 50.
i plan on regearing too.

JacksXJ

Thanks for the reply's!

I have a five speed manual - will that wear the gears any more with 33's than stock? The transmission should be ok - correct?

Any other recommendations for rust protection prior to installing the fender flares?

Thanks again....

OEJ

do you have the 4.0 and do you know ur stock ring gear
either way it will be drivable. but you will still need to regear. the thing with having a 5 spd is the clutch will wear out faster than normal bc of the larger rolling mass.

JacksXJ

Yes its the 4.0l...

OEJ

readmy edit.

millbro

i put the bushwacker flats on mine and just hit the areas with some primer and it's all good. i live in san diego though and it dosn't rain much here. Do your self a favor and ditch the wheel well liners in the front all together when you're doing the fronts. it tells you to cut and trim them, but after a few times wheeling they just started to sag and rub on the tires. i yanked them after that

Slugger

what size lift do you have and wheel back spacing?

JacksXJ

I think I have about 4.5inches now of back spacing on a 7 inch wheel with 31x10.50 - no rubbing at all. I was going to go to an 8 inch wheel with 3.75 or 4 inches of back spacing with 33x12.50 tires.
Not sure of the gear ratio as I bought it used. One weird thing is when I put the bigger tires on the speedometer was reading properly (verified by GPS) - that got me thinking if the previous owner regeared it - but it was an older lady who owned it and she had stock tires on it.....

MECRAM

after in installed the 33's with stock gears 3.55 i could only get into 4th on a down grade. primary gears were 2nd & 3rd. did a lot of research and installed 4.56 with lockers frt & rr. now it will get me just about any where. i do wish there was a 4.33 option for d30 & 8 1/4 this would be optimum for me due to hill climbing on the frwy i'm tacking 3500-4k to keep speeds 65-70mph. planning on BW flares and 34" tires with 16" wheels to lower rev's in third.
always a WIP (work in process)... i mean progress......$$$$$$$$$$$$$