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Old 12-02-2011, 05:48 PM   #1
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Custom "Flat" Fenders like no other.

So I was thinking the other day on a way to make a better flat style fender for alot less then a full replacement fender like MC or PSC or so many others that are hundreds and hundreds of dollars. obviously I could go the tube direction and customize my own, but I dont have a tubing bender and tube is expensive here at any local shops because I live in a small town. its hard enough for me to get sheet and get cuts and stuff. I have to borrow a saw for the bigger cuts. so I have a saws all, dremel/cut wheel/ welder, and a bunch of other general tools.

I have a few projects that I will be working on, but this is probably the toughest and its still in the planning stage. thats where you all come in. You can pitch in ideas and suggestions whenever. I will be building alot of this before cutting into my jeep. So that should save me from any bad bad errors. But the basic plan is to use thinner steel (1/8 inch or so) plate, and alot of the existing fender. Does anyone know what thickness the stock fenders are? that is a good place to start.

Anyways, I plan to remove flares, and there will be a cut across the front removing the front signals to basically a level area. On the bottom of the fender a 1"x.125" piece of steel plate will be run vertically from the grill over to the edge where I will manually bend it at a curve for a 90. Then run it back to the point where the fender bends down. its going to have about 4 inch flares off the existing fenders because of tire coverage in PA. at the point it turns down I will have to make an angle measurement and cut the steel at that angle, then weld and run another piece down to the rocker level, and then another angle cut and another bend piece. or I may just run a straight edge and cut a little round point in the steel. I dont know. Then I will rib it with supports at about 3-4 spots and put 1"x"1 triangle braces from the steel pieces up to the top plate every 6 or so inches on the inside. Then I will have to have plate to lay over top for the flares and the existing fenders will remain but cut. I will use a dremel with a grinding wheel to smooth out all welds and edges. I suppose there will be one ugly bend where the steel plate goes from the flat to the angle down flare. But oh well. Then it will all be primed and bedlined or painted to match my jeep, not sure yet. Thats the basis of the plan though.

So this should cost me about, 30 bucks in 1" steel, and a bit more for the plate. not sure on the cost for that yet. I will budget like 100 but it should be a good bit less. So I should have some flat fenders for about 150 bucks all said and done after welding equip and paints etc.

Also, since I will have removed my sahara flares, I can resell those for a nice price so these fenders should nearly pay for themselves.

I know it wont be as easy working on them, as it is planning them but thats the fun of making something yourself.

You can lay out any suggestions or ideas you have if you want. this is still in the planning stage so I am open to changing almost anything!

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Old 12-02-2011, 10:07 PM   #2
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Ill be watching .

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Old 12-02-2011, 10:25 PM   #3
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Originally Posted by crtaylor
Ill be watching .
It should be interesting. First thing on the menu is a frame width stinger/winch plate. I order parts this weekend now that I found them all. Then break out the welder

It's either fenders or sliders next. I still have to decide how I'm bending the steel plate.
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Old 12-02-2011, 10:27 PM   #4
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Old 11-08-2012, 11:21 PM   #5
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I thought I would revisit this. I am currently working on a new design for a highline and have a few potential routes in mind at this point. Either working with MCE and creative a hiline version of their flexible fender, or making my own tubes. Either one would probably reuse the stock inner, but I have considered using genrights inner which comes with excess material so it can be used for custom fenders.

If anyone has any information on anything relating to this feel free to share. In the brain storming phase as I am also keep my eyes open for axles, but spending most of my time wheeling and enjoying the jeep.
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Old 11-09-2012, 07:32 AM   #6
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I am gonna make my own out of 1 1/2" square tube. It will match my sliders and be strong. Gonna make my own inners. Maybe from aluminum but not sure yet.

Should be cheap and strong.
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Old 11-09-2012, 07:58 AM   #7
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one way to bend 1/8 inch metal is to clamp heavier pieces of steel on both sides of the piece you want to bend and then heat it uniformly along the bend line..I usually clamp them about 1/8 inch back from where I actually want the bend..when I got my rock crawler the front fenders had been cut flat.they may have looked good when they were first done but cutting them had removed a lot of support so they soon were out of shape..I used 1/8 inch steel to cap over the existing fender,then added 1/4 x 3/4 flat metal around the edge and for the frame to hold the turn signals..last I used 3/16 x 4 flat to go down the back edge to meet the poison spider side pieces that were already there since that was the thickness that they were...I attached all this with allen head cap bolts that matched a lot of the other existing bolts.this was just an easy way for me to do it without having to disassemble anything.in georgia we don't have to cover the tire but no reason they couldn't be built wider if desired
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Old 11-11-2012, 07:56 PM   #8
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Wow those look really good. Nice work
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Old 11-13-2012, 03:02 AM   #9
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I've never seen springs like that can you explain that please... Is that custom also?
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Old 11-13-2012, 03:04 AM   #10
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I've never seen springs like that can you explain that please... Is that custom also?

Those are custom coilovers
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Old 11-13-2012, 06:42 AM   #11
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Thanks guys those look nice. I have a friend with a manual sheet bender/press, but don't like using other peoples tools unless I need. I am really leaning towards working with an MCE hiline, as the PA trails tend to be unfortunately narrow. Trees are as much a danger as rocks. Plus I like the fact that I don't have to work about fender clearances when leaned hard toward a rock.
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Old 11-13-2012, 06:54 AM   #12
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Wow those look really good. Nice work
thank you.I just enjoy designing and building my own parts when I can.I owned a welding business where I designed and built farm equipment for many years and have also built custom harleys in my spare time for the last 35 years.Now that I am retired and the chopper market has hit bottom,I spend most of my time on jeeps.I like one of a kind items and saving money.there are more one of a kind items in a thread that my wife started in the yj forum titled "what I did to my yj this week" if you care to check it out
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Old 11-13-2012, 07:01 AM   #13
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I've never seen springs like that can you explain that please... Is that custom also?
yes,they are Balistic coil over air shocks.this jeep has a lot of custom parts on it.I am not trying to promote a sale here but if you would like to see more pics and read specifics on it they can be found in the for sale section under the title rock crawler,97 tj
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Old 11-13-2012, 01:01 PM   #14
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I bought some prebent tube from www.jeeptubes.com to make my fenders. I went with the 'narrow hi-line' version for mine, but they have a standard design available. They basically come out looking like PSC fenders one assembled and skinned in 1/8" plate.

For $90, it's hardly worth the headache if you can't bend tube yourself.


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Old 11-13-2012, 01:14 PM   #15
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I bought some prebent tube from www.jeeptubes.com to make my fenders. I went with the 'narrow hi-line' version for mine, but they have a standard design available. They basically come out looking like PSC fenders one assembled and skinned in 1/8" plate.

For $90, it's hardly worth the headache if you can't bend tube yourself.

I tried ordering their highline tube kit and they wouldn't ship them to me last year...

I used their stinger tube when I made my bumper since I don't have the tools to bend DOM, just pipe.

They have good stuff and a nice price.
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Old 11-13-2012, 02:08 PM   #16
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Hmm, that's strange they wouldn't ship it to you. You know you have to pay them, right? Hahahahaha.

My tubes and plate are sitting in my garage ready for me to pay them some attention.
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Old 11-13-2012, 06:52 PM   #17
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Hmm, that's strange they wouldn't ship it to you. You know you have to pay them, right? Hahahahaha.

My tubes and plate are sitting in my garage ready for me to pay them some attention.
No I thought they were free darn it! I had the hiline tubes and flares and the site said pick up only.

I don't need tubes/ hiline til the axle swap is done so Ill be focusing on that for now.

Let me seem ours when you are done. Going with a flare? I need one for pa legality. Woohoo.
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Old 11-13-2012, 08:33 PM   #18
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Hey Golden check out this local PA guy that I am friends with. he has some great stuff, and may be some help with the PA laws on how to build.
TRAILTUBES.COM | D.I.Y. SUPER BEEFY TUBING KITS FOR
JEEPS – BUILD YOUR OWN

He also has free shipping!
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Old 11-13-2012, 11:20 PM   #19
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My buddy Jared mentioned them just the other day. I will def be looking at them once I get the axle finished.
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Old 11-13-2012, 11:31 PM   #20
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Rick is great. I have the rear fender kit in my garage. but its going to be a bit before i get to build on my keep
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Old 11-13-2012, 11:33 PM   #21
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Yeah I feel ya. I'm a full time student so I only get to do big projects over breaks. So not that much.
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Old 12-30-2012, 12:25 PM   #22
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Hey Golden I'm not that far from you and my friend has a bender. We are getting ready to start my fenders next week. I'll post up some pix for you. If you need to bend up some DOM he could bend it for you, probably real cheap. If you like mine when I'm done we'll have a pattern to go off of. Not to change things but check his FB page Redneck Fab. He's building body armor and tube flares for his XJ.
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Old 12-30-2012, 12:26 PM   #23
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Hey Golden I'm not that far from you and my friend has a bender. We are getting ready to start my fenders next week. I'll post up some pix for you. If you need to bend up some DOM he could bend it for you, probably real cheap. If you like mine when I'm done we'll have a pattern to go off of. Not to change things but check his FB page Redneck Fab. He's building body armor and tube flares for his XJ.
I'll check it out. Actually have a guy who can bend us DOM now so fixed that issue, I won't be doing fenders until the 8.8 is complete though.
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Old 12-30-2012, 12:27 PM   #24
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Mine also are going to be street legal. I'm running 36's on 8's
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Old 12-30-2012, 12:28 PM   #25
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If your on FB look me up. Scott Dinger. Keep in touch
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Old 12-30-2012, 02:17 PM   #26
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I'll look you up. Hit me up with the fenders when your done. I will be doing 35s or 37s eventually, gota keep mine legal too.
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Old 12-30-2012, 11:11 PM   #27
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Will do!!!

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