1. Welcome to Tacoma World!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all Tacoma discussion topics
    • Communicate privately with other Tacoma owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

How to modify fenders for bigger tires.

Discussion in '2nd Gen. Tacomas (2005-2015)' started by GSK9 B1T3, Jan 29, 2011.

  1. Jan 29, 2011 at 1:38 AM
    #1
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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.

    [​IMG]

    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.

    [​IMG]

    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.

    [​IMG]

    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.
     
  2. Jan 29, 2011 at 1:44 AM
    #2
    BartStar

    BartStar Well-Known Member

    Joined:
    Jan 7, 2011
    Member:
    #48847
    Messages:
    434
    Gender:
    Male
    pa
    Vehicle:
    2011 Tacoma 4X4 Double Cab, 6 speed man
  3. Jan 29, 2011 at 1:48 AM
    #3
    RelentlessFab

    RelentlessFab Tacoma offroad armor fabricating beast Vendor

    Joined:
    Feb 17, 2008
    Member:
    #4772
    Messages:
    14,194
    Gender:
    Male
    First Name:
    Eric
    Eastern side of the Sierras: Sparks, NV
    Vehicle:
    07 SR5 4x4> 03 SR5 4x4 total> 14 Crewmax TRD
    Had tons on the old Taco's.... new Tundra is pretty stock
  4. Jan 29, 2011 at 7:20 AM
    #4
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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 :D.

    Relentless - Thanks for posting those pics. :cheers: If you feel like sending me some more pics of the inner well that would be greatly appreciated!
     
  5. Jan 29, 2011 at 7:37 AM
    #5
    08pretaco

    08pretaco Almost there

    Joined:
    Sep 26, 2008
    Member:
    #9502
    Messages:
    9,059
    Gender:
    Male
    First Name:
    Oliver
    az
    Vehicle:
    2014 Tundra 4x4 CM 5.7L SR5
    AFE pro dry s, Husky X-act Contour
    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
     
  6. Jan 29, 2011 at 8:07 PM
    #6
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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.
     
  7. Jan 30, 2011 at 12:23 AM
    #7
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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. :facepalm:

    [​IMG]
    :laughing:

    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) :anonymous:.

    Ideas....

    [​IMG]
     
  8. Jan 30, 2011 at 12:38 AM
    #8
    907taco

    907taco Alaskan Assassin

    Joined:
    Mar 27, 2010
    Member:
    #34091
    Messages:
    1,358
    Gender:
    Male
    First Name:
    Bobby
    Alaska
    Vehicle:
    2010 BlackSandPearl 4x4
    ultimate lift kit ( toytec ) ome dakar leaf pack , w/ extended length billies, LR uca's, Pro comp 7089s, KM2's 285 70 17, neoprene seat covers, weather techs, CBI sliders w/kickout, URD ss, cab mount chop, VHT night shade tint>tails,3rd B-light. Debadged. Grillecraft grille, rear diff breather mod. CBI Moab front bumper, warn M8000 winch, HID kragens 7", Hella's micro fogs. retrofit headlights HIDS, LED solutions maps/license! 886 back up light mod,
    keep up good work bro, i for one would not tackle this mod. It looks like your doing a great job man..!!!!!
     
  9. Jan 30, 2011 at 12:48 AM
    #9
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    Thank You.
     
  10. Feb 1, 2011 at 3:40 PM
    #10
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    UPDATE

    Cut original mounts all the way off. SAVE THEM! We will use them to remount the fender flare and water guard.
    V---------------------------------------------------------------------------V
    [​IMG]

    Cut fender as shown.
    V---------------------------------------------------------------------------V
    [​IMG]

    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
    [​IMG]

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

    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
    [​IMG]

    With the extra metal cut and bend some miniature L brackets
    V---------------------------------------------------------------------------V
    [​IMG]

    Reinforce the fender
    V---------------------------------------------------------------------------V
    [​IMG]
    [​IMG]

    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
    [​IMG]

    To be continued......
     
  11. Feb 4, 2011 at 6:50 PM
    #11
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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.
     
  12. Feb 4, 2011 at 8:03 PM
    #12
    Tim A

    Tim A Well-Known Member

    Joined:
    Dec 26, 2009
    Member:
    #28169
    Messages:
    448
    Gender:
    Male
    Montana
    Vehicle:
    2011 TRD Offroad 6 spd Double Cab
    You got balls! Good luck I'm sure it will turn out looking great.
     
  13. Feb 4, 2011 at 8:21 PM
    #13
    island808

    island808 Me l've got brains.

    Joined:
    Oct 9, 2010
    Member:
    #44414
    Messages:
    1,892
    Gender:
    Male
    First Name:
    Jedediah
    hawaii
    Vehicle:
    '10 6speed 4x4 access cab
    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
     
  14. Feb 5, 2011 at 5:56 AM
    #14
    DrRabbitFurHead

    DrRabbitFurHead Yeah, there's a TSB for that!

    Joined:
    Jun 18, 2009
    Member:
    #18625
    Messages:
    1,058
    Gender:
    Male
    Salem, VA
    Vehicle:
    X-treme Off Road Edition (4x4)
    Icon Extended Travel Coil Overs, Fox Rear Resi 8-Way Adjustable Shocks, Light Racing UCA's, OME Rear Leafs, M/T Classic Locks 17x9, Nitto T/G (285/70/R17), 5mm Billet Aluminum Spacers, Demello Sliders, All Pro Front Plate Bumper & IFS Skid Plate, PIAA 510's, Doug Thorley Long Tube Headers, O2 sims, Rear Timbren's & U-Bolt Flip Kit , 3* Rear Axel Shims, Extended Rear Brake Lines, 48" Hi-Lift with a ton of accessories, Wet Okoles, TRD bed mat, Borla Air Filter, Garmin Nuvi 765T, Viper 5901 remote start, 50% tint.
    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?
     
  15. Feb 5, 2011 at 7:23 AM
    #15
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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.

    :D 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.
     
  16. Feb 5, 2011 at 7:26 AM
    #16
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    ^--- Thats what she said :rofl:
     
  17. Feb 12, 2011 at 2:57 PM
    #17
    theduck911

    theduck911 Max's Canadian Twin

    Joined:
    Oct 28, 2010
    Member:
    #45374
    Messages:
    4,041
    Gender:
    Male
    First Name:
    Max
    Northwestern Ontario, Canada
    Vehicle:
    Locked and Geared!
    So what's the result of these fenders?[​IMG]
     
  18. Feb 12, 2011 at 6:35 PM
    #18
    RelentlessFab

    RelentlessFab Tacoma offroad armor fabricating beast Vendor

    Joined:
    Feb 17, 2008
    Member:
    #4772
    Messages:
    14,194
    Gender:
    Male
    First Name:
    Eric
    Eastern side of the Sierras: Sparks, NV
    Vehicle:
    07 SR5 4x4> 03 SR5 4x4 total> 14 Crewmax TRD
    Had tons on the old Taco's.... new Tundra is pretty stock
    X2,
    any more progress? Does it look like my fenders yet? :D
     
    ChadDenver likes this.
  19. Feb 12, 2011 at 10:35 PM
    #19
    island808

    island808 Me l've got brains.

    Joined:
    Oct 9, 2010
    Member:
    #44414
    Messages:
    1,892
    Gender:
    Male
    First Name:
    Jedediah
    hawaii
    Vehicle:
    '10 6speed 4x4 access cab
    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.
     
  20. Feb 12, 2011 at 11:37 PM
    #20
    GSK9 B1T3

    GSK9 B1T3 [OP] Well-Known Member

    Joined:
    Dec 2, 2010
    Member:
    #47054
    Messages:
    93
    Gender:
    Male
    First Name:
    Another One
    Washington
    Vehicle:
    TRD Rugged Trail ED
    Toyotec Ultimate 3" TC UAC 305/70 R16 Breather Mod Front fender Mod Steel Brake Lines All around
    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.

    [​IMG]

    [​IMG]

    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.
     
To Top