XJ Fender Trimming?

[desertdawg]

I plan on trimming the fenders on my son's XJ in the near future and wanted to get some suggestions on how to do it before I start. Some of the questions I have include,

What cutting tool is best for the job?

The only cutting/grinding tool I have is a Dremmel tool, will this work?

Any tricks of the trade?

What to do and not to do?

etc, etc.

Thanks in advance!:)

[k7mto]

I can't answer XJ specifics, but for general cutting....

A plasma cutter would be ideal, but you'd have to find someone to lend you one or bring the XJ to. Air powered snips might be nice too, but most of us end up using a grinder with a cut disk, a jigsaw or a sawzall. They work ok if you take your time and are careful.

Tape over the cut line (mark your line on the tape) for a cleaner cut.

[Simon]

Mike use a body saw. Small blade with the best accuracy!

[Crawldit]

When I cut I started out with a cut off wheel. I ended up going out and buying a sawzall and then life was much better.

[cw50must]

I used a grinder w/cut off wheel.

[fallx13xflights]

I used a dye grinder (spelling?) and covered the cuts with the door trim!

[Phx Cobra]

I used a Angle Grinder with cutoff wheel on my TJ, I would not recommend it as the sole tool, a sawzall or Jigsaw would make it easier and cleaner.

[Offroader5]

I used a 4 1/2" grinder with the thin (1/16") cutting wheel. It was a very clean cut and only had to slightly hit the edge with the grinding wheel afterwards to get it just right. Only tricky part was turning the corners on the upper part of the wheelwell with that large of cutting wheel.

http://img.photobucket.com/albums/v126/offroader5/Fenders%20And%20Sheetmetal/rearrockerwell-after1.jpg

[RickBeer]

A really GOOD steady hand :p

[TomHatch]

x2 on jig saw with a metal blade or body saw

[GLEN REAMS]

i tryed a body saw on one of my fenders it worked the best took a really long time cuz my body saw sucked then i used a dremel it turned out good but took way to long so on the other 2 fenders i used a angle grinder it was really fast cuting but they turned out like dog crap i couldnt keep my hand straight enough so i got them off even and really looks like crap

[NVRSTUKXJ]

I used an air cut off wheel.....the fronts were easy.....when I took off the flares, they left a nice dirt line to follow......be careful in the back....if you cut too far you'll go thru the pinch seam which will leave you with a separated interior/exterior......I used the cut off wheel to make cuts about every 2 inches from the outside edge just to the seam....then used a hammer to roll the fender up inside.....if you're in mesa you can come by and take a look if you want.....

[twstdtj]

Ive done lots of cutting, and next to the plasma your best bet would be an air body saw, with a fine/narrow blade. Tape your line, and cut away.

my .02

Jeff

[1toughxj]

Mike, are you wanting to remove the flares or keep them on?? That's gonna be something that you will have to consider. Did you end up going with the 35's??

[DUFFER]

I used a sawzall and a cutting wheel. If you cut to far up on the rear, be prepared to weld the seams back together.

[Triple-XJ]

I would use a BODY SAW.. I picked mine up at Harbor Freight. I saw them on sale untill 01-15-07 for $20. Its the same one I used on 6 or so Jeeps. I like it It has a small thin blade that cuts and turns with ease, just keep it oiled.

I would not use the saw-zaw, only as a last resort. They have such a long stroke, if your not very carefull, the front fenders could end up distorted.

When cutting the rear, I just went to the first lip, before the spotwelds, relief cut the corners in a few spots, and rolled the rest up unde, with a hammer.

[desertdawg]

Thanks for everybody's suggestions. I started the front fenders with a saws all and it's almost impossible to see where your cutting because the fender is vibrating so bad.:eek:

I'll swing by Harbor Freight and pick up a body saw to finish the rest.

Thanks again!:)

I have another question for you XJ guys.

I tested the 35's out in the front and on full turn the tires rub real hard on the lower control arms. Will wheel spacers solve this issue and if so what size spacers should I get?

[AZXJ]

Has to do with rim backspacing.. It will not effect anything other then the paint on the arms..

[xjdoyle]

most people with tires over 10.5 wide rub the lower arms i have 13.5 with tires that rub my lower arms and has for the last 3 years it just rubed the paint of but did nothing to the arms so i would just not turn that sharp!

[Markos]

A plasma cutter would be ideal, but you'd have to find someone to lend you one or bring the XJ to

I disagree. I doubt that the poster got their hands on a plasma anyway. If they did, I think he/she would find that the end result would be much more accurate with a cutoff disk or even a recipricating saw. You are cutting through sheet metal not 3/4" plate...

I would equate the differences to drawing a circle by hand versus using a stencil...

[desertdawg]

Well I'm done with the front fenders. I ended up using a 41/2 inch angle grinder to finish them up after cutting most of the sheet metal away with a saws all. I don't have air tool capability so I couldn't use a body saw. I think they turned out pretty good. I'll put some trim around them later. Next comes the rear.

Trimmed with 35's
http://www.virtualjeepclub.com/attachment.php?attachmentid=8874&stc=1&d=1167274890

http://www.virtualjeepclub.com/attachment.php?attachmentid=8875&stc=1&d=1167274890
Photo with 35's before trimming fenders.
http://www.virtualjeepclub.com/attachment.php?attachmentid=8876&stc=1&d=1167274890

[joedokes28]

That came out pretty nice. Good work.

[desertdawg]

I had my old 35's swapped over to my son's wheels that were on his 31's and took it for a short spin at Bulldog Canyon to see how they stuffed up into the fenders. Rear fenders still need trimming and I think I need a bit more off the front.

While I was at Discount getting the tires swapped I met AZCharlie's twin brother Emery who is the manager at the Discount Tire on Power & Mckellips. Very nice guy! He gave me some of his business cards to pass out and told me that he would take care of us. :)

http://i20.photobucket.com/albums/b208/ddawg_/IMG_0123.jpg

http://i20.photobucket.com/albums/b208/ddawg_/IMG_0141.jpg

http://i20.photobucket.com/albums/b208/ddawg_/IMG_0136.jpg

[Gordon]

WOW! The Cherokee looks great! Nice job on the trimming. What ever you do, 35's are going to rub on the lower controll arms, and if you go to spacers or far offset rims, then you have to deal with the tires rubbing on the fenders pretty bad. It's a catch 22. It's looking great! Take your time and have fun with it.

[GLEN REAMS]

that looks great and yeah emery is pretty cool guy i had no idea he worked there tho but wow that xj has grown over these past few months

[dcm1086]

I really like the way it looks Dad!!!!!!!!!!!! Thx. :)

[desertdawg]

Your Welcome! It's going to be hard giving you back the keys.:D

[1toughxj]

Looks good Mike!!!