How to modify fenders for bigger tires.

First thread so I will keep it to the point. I really liked how RelentlessTaco and All.On.Black modified their fender wells. So after talking with them I decided to learn how to do this myself.

I want to let you know that I have no experience with body work. If you try this I am not responsible for any thing related to you or your truck. Not to mention your a bit crazy already.

This thread will be more in detail (more pics and directions) once I have finished. Until then I will slowly add to it as I finish up the project

Step 1 - Take off front bumper.

Step 2 - Remove side fender covers.

Step 3 - Pull out the water guard.

Step 4 - I measured out two inches all the way across the fender. The X's are the locations for the plastic pins that will hold the wheel well water guard in place after they are bent like tabs and re-drilled or however I decide to go about re-making the tabs.



Keep the following as a tab. I accidently cut it off but I am going to bend it into an L bracket and epoxy it on so I can use the tab space to hold the fender flare on.



Step 5 - Cut away the fender in chunks

Remember when you bend the tabs over the paint will split away. Make sure to score a small line where you intend to bend so the paint doesn't start to peel upwards toward the visible portion.



Step 6 - Cutting the fender flares to fit and still look like stock.

Step 7 - Drill new holes for fender flares to attach to fender.

 

http://www.dewalt.com/tools/cordless-saws-reciprocating-saws-dc385k_2.aspx

 

Thought I'd throw this in here too. Link to pics of my hacking endeavors
http://www.tacomaworld.com/forum/2nd-gen-builds/17769-relentlesstacos-build-up-13.html#post2159816

 

BarStar - I thought of using that tool. As I am very unexperienced with cutting I feel a tad safer using the dremel because it is small and I can control it. Though the dremel cuts through that thin metal with ease. But yes I may graduate after a few fenders .

Relentless - Thanks for posting those pics. If you feel like sending me some more pics of the inner well that would be greatly appreciated!

 

So I asked RElentless also but did you have to drill mounting holes or shorten the flares? If not wouldnt the tabs on the fenders and flare just match up with the tabs?

Sorry i havent physically seen the other side of the flares so idk if there is a specific place the tabs go into. Can you post a picture of the inside of the flares

 

Well I am still in the trial and error stage of getting the flares done correctly. I will let you know as soon as I figure it out. This is definitely the hardest part of this modification.

 

Alright well I think I have run into the most difficult part so far. I was not taking my time and this is what happens.




The problem is this. When removing more fender the mounts now become further apart. This makes the fender want to sit higher and further away from the front of the actual fender (no pic, was to angry at myself at the time) .

Ideas....

 

keep up good work bro, i for one would not tackle this mod. It looks like your doing a great job man..!!!!!

 

Thank You.

 

UPDATE

Cut original mounts all the way off. SAVE THEM! We will use them to remount the fender flare and water guard.
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Cut fender as shown.
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Connect the mounting pieces to the stock mounting location by re-inserting the squares and screw the fender mid section like so. I decided to grind the paint off because I am going to epoxy the metal to the inside of the fender.
V---------------------------------------------------------------------------V


Now remount the original fender and align the two under pieces to where they work with the natural curve of the fender.
V---------------------------------------------------------------------------V



Once you have the under pieces where you want them on the fender go ahead and put on the rest of the fender via the clips. Once on tape the under pieces to the fender.
V---------------------------------------------------------------------------V


With the extra metal cut and bend some miniature L brackets
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Reinforce the fender
V---------------------------------------------------------------------------V



Epoxy the L brackets in place. (EDIT: When I took the clamps off the plastic tried to move thus cracking through the small amount of epoxy. This gave me a chance to properly prepare the glue sight IE: Get all paint of glueing surface and scuff area to glue bracket to.) I am going to go over with a hot glue gun as well.
V---------------------------------------------------------------------------V


To be continued......

 

Epoxy is to brittle. For this job. I sanded the areas down and am now going with fiberglass and filler to fix the gaps

Also I decided to use small screws to reattatched the flare mounting bracket.

 

You got balls! Good luck I'm sure it will turn out looking great.

 

I didn't know the duty cycle on a modeling tool would allow cutting all the way a full scale car wheel well.
HEE--larious

 

So if you were to do this again would you recommend cutting the plastic fender flare first, then using the flare to make sure the tabs in the fender ended up in the right place?

 

Dremel - For the inexperienced it is easy to manipulate.

Nope - Because I marked where the tabs should go before chopping them off it was easy enough to replace the clips. Now I might measure the flare and cut the flare before I do the metal cutting. This would probably make the fender and flare flow a bit better.

Thank You.

I thought of that BUT I couldn't take the look of the fender w/out the fender flare. Not to mention this is the first time I have ever done anything like this so its more of an adventure.

 

^--- Thats what she said

 

So what's the result of these fenders?

 

X2,
any more progress? Does it look like my fenders yet?

 

good on ya for cutting fenders rather than resorting to silly suspension lifts for tire clearance.
Right thing to do and handy way to do it.

Its either that or body lift in my humble opinion... at least for what most are trying to do.

NOW for the magic act.. make an IFS truck flex.

 

Well I ended up using fiberglass and fiberglass bondo stuff to get these damn fenders to look somewhat like stock. Took many hours and I was finally just done so I painted them and slapped them back on!

I won't say they are perfect but I like the look of a skinnier flare.





I apologize for the crappy low light droid pics but I was in a rush. If you are looking at them in person you can see where there are some imperfections and a few spots where bondo meets plastic. Overall i am not to upset considering this is the first time I have ever done anything like this. I have two more fenders to fix my methods.