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A couple of pics: Bushwacker cut outs w/pinch weld vs. stock

Discussion in '1st Gen. Tacomas' started by Seventh, Jun 5, 2013.

  1. Jun 5, 2013 at 3:04 PM
    #1
    Seventh

    Seventh [OP] Insert witty title here

    Joined:
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    Chris
    Boston, MA
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    2001 Reg Cab 4x4
    I'm in the middle of installing the BWs and have one side done. It's a pretty long install, but so far I haven't run into any problems other than a couple of the chrome torx screws being a hair too short.

    These are the cut-outs, and I did the pinch weld mod too since it's part of the install anyway. My tires are 33x10.5x16 on the stock rims, with a 3" lift. Quite a big difference in tire clearance, and it finally doesn't rub at full lock. A good bit of work but IMO worth it.

    Stock:
    [​IMG]

    Bushwackers:
    [​IMG]

    Stock:
    [​IMG]

    Bushwackers:
    [​IMG]

    Stock:
    [​IMG]

    Bushwackers:
    [​IMG]
     
    Last edited: Jun 5, 2013
  2. Jun 5, 2013 at 6:44 PM
    #2
    Lumpskie

    Lumpskie Independent Thinker

    Joined:
    Apr 20, 2013
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    #102450
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    1,894
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    Colorado
    Vehicle:
    '96, 4x4, v6, manual hub
    Toytec 16" coilovers with Tundra Bilstein 5100s, Light Racing UCAs, Alcan Leafs with Orbit Eyes, 12" Bilstein 7100 short Bodies, ARB rear locker, 33x12.5 Duratracs, CBI sliders, Bushwacker fender flares, self made front bumper, M8000, Vision X 6.7" Hi/Lo Beam HIDs, full skids, Inchworm dual case setup - 15º clocking
    Looks like you gained some good clearance towards the back of the truck. Besides the pinch weld mod, is there anything that these flares do differently than stock?
     
  3. Jun 5, 2013 at 7:12 PM
    #3
    Seventh

    Seventh [OP] Insert witty title here

    Joined:
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    #91582
    Messages:
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    Chris
    Boston, MA
    Vehicle:
    2001 Reg Cab 4x4
    Yeah, these are the cut-outs, so you have to hack your panels up to get them on. I chopped about an inch off of the front one (towards the door) and about 1.5" on both sides of the back.

    Here's the cut line for the front:

    [​IMG]

    Plus copious amounts of priming and grinding (all of the primed area is under the flare)

    [​IMG]

    And here's the cut line for the back. You cut about this much on both sides in the rear, I just didn't get a pic of it.

    [​IMG]

    Post cut:

    [​IMG]

    And after priming and grinding it all down. (The blue tape in this pic is just so that I don't get overspray on the paint. I just masked it and stuck a piece of cardboard down at the edge.)

    [​IMG]

    I used a cut wheel off of my compressor to do the actual cutting - a sawsall would bounce too much and risk bending the hell out of the panel. It took a bit longer but the lines were nice and straight. Then I went OCD on the thing and laid about 10 coats of primer, two coats of rust sealer, black enamel on top of that and then some rust proofing clear. My truck's no beauty queen but there's no way in hell these edges will ever rust out. :D

    It's a lot of work, and a lot of this:

    [​IMG]

    But so far so good and the fact that it doesn't rub at all, even in reverse at full lock (which was always the worst for me) is just awesome. I did it mostly by myself and without taking the wheels off. It'd be a lot faster with a lift, but it wasn't too bad this way either. The only real pain in the ass was hammering out the pinch weld, haha.
     
    Last edited: Jun 6, 2013
  4. Jun 6, 2013 at 9:46 AM
    #4
    Lumpskie

    Lumpskie Independent Thinker

    Joined:
    Apr 20, 2013
    Member:
    #102450
    Messages:
    1,894
    Gender:
    Male
    Colorado
    Vehicle:
    '96, 4x4, v6, manual hub
    Toytec 16" coilovers with Tundra Bilstein 5100s, Light Racing UCAs, Alcan Leafs with Orbit Eyes, 12" Bilstein 7100 short Bodies, ARB rear locker, 33x12.5 Duratracs, CBI sliders, Bushwacker fender flares, self made front bumper, M8000, Vision X 6.7" Hi/Lo Beam HIDs, full skids, Inchworm dual case setup - 15º clocking
    Good write-up. Looks good too!
     
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