Cutting Bedsides For HC Bumper ?

Cutting my buddy's bed for his HC bumper soon. I have a grinder w/a cut-off wheel, jigsaw w/a fine tooth metal blade & a sawzall w/a fine tool metal blade. It seems most use a cut-off wheel on a grinder but why not a jigsay w/a fine metal blade? Seems the jigsaw would make a much nicer cut w/less chance off getting off the 2 foot long line.
Yes/no?

 

The teeth of those blades even the fine toothed ones can grab the metal and mess it all up bad. A cutoff disc and steady hands work really well. Also tape the cut line and a bit above it with painters tape. Quadruple check your measurements.

 

What do people use when the trim their fenders, in an arc, for larger tires?

 

cutoff wheel then flap disc to get it evened out. Takes a smooth hand

 

Grinder works great with minimal to no paint damage if you take it slow and easy, thats what i did on mine. And i would love to see someone use a jigsaw on flimsy sheetmetal and make anything resembling a straight line.

 

There seem to be lots of videos out there on this. Check the bumper manufacturer and see if they have a video on youtube. Could be really helpful.

 

I've cut ~6 trucks bedsides for HC bumpers and used an angle grinder each time. To trim my fenders for larger tires, used a jigsaw. You have to go extremely slow with the jigsaw and it's easy to get off the line. I can make a damn near perfect HC cut with an angle grinder.

My trick is (after the line is drawn) start cutting extremely slow, barely any pressure. Not enough to cut through, but enough to scribe a line in the metal. Once you have that line, then make another pass, cutting all the way through. The scribe helps keep you on track.

edit: And I use a 6" disc and cut straight through the fender flare, down to the fender. Much much easier than removing the flare, and still makes a perfect cut.

 

I wish!

 

what model angle grinder?

 

Nothing fancy, an older model of this.

https://www.homedepot.com/p/300476867

 

if you have a nice sharp find metal blade the jigsaw will work well. That is what I used when trimming fenders. As others noted they can grab and bend the sheet metal easily but if you catch it its not bad. I generally noticed then when the blade started to do dull. Generally after the first fender or so. If you have good control over the cut-off wheel it works. I had someone install my bumper when I picked it up. It was a decent job. I feel I could have done better with the jig saw but overall both methods work. The cut off wheel chipped some of the paint and sometimes getting an even cut can be tough but depends ho good you with it.

 

def would 2nd that by making a scribe. biggest mistake is going at it with a grinder too fast.

 

A jig saw will vibrate the crap out of your material and make a mess of things. I used a Dewalt cordless angle grinder with a cutoff wheel and it did great. The first issue was the fender flare is a little deep for a 4.5" disc. The other problem being the grinder melts the flare while it cuts. I would highly recommend using just the grinder, but with a 6" disc. Also have some color matched touch up paint for the edges

 

I used a q-tip to paint the open edges and protect from rust. I also put some edge trim on to complete the look.

You should also cut the exhaust just after the rear axle (I assume in Texas this is fine, in cali im afraid I might not pass smog with a modified exhaust)

My best advice is to take your time and tape/mark it all before cutting anything. You can only cut once so measure thrice. If you have more questions feel free to PM me. I've got a 2009 with BruteForceFab HC rear bumper I installed solo in my driveway.

 

Think you could get away with a slip on joint?

Slip it when you have to smog and pull it off when you're rolling?

I cut my fenders with a Air Body Saw and a very fine tooth blade, took my time went very slowly then cleaned up with a flap disk on a 4" grinder.

When I do my bed sides I'll do the same except as I saw Brian do at Windrock, cut about 1/2-3/4" below where I want the line then carefully roll it up so I have a nice curved lip with a little rigidity rather than a floppy jagged razor edge.

Looked clean and was done great.

 

It's all about the visual inspection here. If the tech doesn't care it's fine, but if they do I'll be in for a retest. We have the strictest laws in the country regarding smog checks and since Dominic Toretto hit the scene its only gotten worse. If your car isn't completely stock they can fail you just on a visual inspection.

 

Wow that's kind of pants on head retarded.

Like seriously. Lopping off 12" of pipe doesn't change the emissions, or even the sound for that matter it's after the muffler...

Thank God I life in the DGAF state where we have the coastal jetstream to magically dissapoof all emissions.

 

Yeah, its super lame here. Technically we are supposed to use oem exhaust parts only. Its making it hard to even get motorcycle exhausts even though they don't have to get smogged.