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Old 12-01-2011, 01:17 AM   #1
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DeFender install pictures (lots)

Enclosed are a lot of pictures of my DeFender install. Pretty basic stuff. Tools needed to complete the task are a socket and wratchet, a cutting instrument, and a file. I chose a 4.5" grinder with a cutoff wheel. Works really fast. The file is to smooth out the edges.

My apology in advance to the fine folks at Poison Spyder Customs. I didn't read their instructions. Actually, I didn't even OPEN their instructions. So there is probably some things YOU can do better.

Overall time in the install, from start to finish was around 3 or 4 hours, not counting the time at the body shop for paintwork.

To the moderator: If I've posted this in the wrong section, please move it. Thanks. TreeClimber

Finished pictures.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:19 AM   #2
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Start by unbolting the old fender. You will remove it, and reuse the inner fender. It's easy. 3 bolts secure the underside of the outer fender to the grill. 3 more bolts secure the underside of the inner fender to the grill. 1 bolt secures the above fender to the grill. Remove these and save for later.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:25 AM   #3
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Now is when I disconnect the battery, and un bolt the top accessories from the engine bay, and set them on top of the motor, as best you can. (In my case, I've already done an engine swap, and most of my accessories & wiring will be different from yours)

Then unbolt the battery tray from the battery tray support. It's four bolts in the inner fender. Since the battery is also out, unbolt the battery tray from the battery support. Then unbolt the 4 bolts which secure the fender to the body tub. The battery support bracket is then removed from the tub with 5 bolts.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:32 AM   #4
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Congrats! You now have your fender in your hand. In my case, I've already removed my fender flair, and, as you will notice from the pictures, I have a blue fender and a green fender intermingled in some pictures. Don't ask. Anyhow, it's cutting time! I used 1" masking tape to mark out my cut lines. The outer fender is to be shed, but you want to have a lip that is used under the DeFender, so the one inch overlay will allow you to have a smooth (factory-like) transition from factory to aftermarket. You want that 1" of painted surface. Don't cut on the inner tape line, but the outer tape line. (sorry about the glare in the pic) You cut the line on the inner fender, right at the corner. The two cut lines are joined at the top. You then notch out that little piece under the bolt hole in the last picture.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:33 AM   #5
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Here's what your new fender looks like now.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:38 AM   #6
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Now install your DeFender outer fender, just like you removed your old fender. Once it's loosely bolted up (snug at the body, loose at the grill), slide your new inner fender inside the DeFender and loosely bolt it to the grill. Coax the two together, and hold tight. I used my TJ bottle jack, from the shock front shock tower to hold everything so I could drill my holes. Drill 1/4 inch holes, bolt together with the provided hardware.
You can also see the discard pieces from the fender. Disregard the big hole in the fender top, that was a test hole for my new front blinkers.

(I also forgot to put drill on the tool list from post 1)
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:45 AM   #7
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Here's some fit and finish pictures of the underside, plus the blinkers. The DeFender comes with the 3/4 LED light hole, prepped, in the corner. I sourced my LED locally, but wish I had just ordered it with the fender. The larger lights were done for aesthetic reasons, as I have matching rear lamps already.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 01:47 AM   #8
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I'll also post some 'poser" pics soon, weather permitting.
Hopes this helps with any questions you may have about if it's an easy task. It is easy.

Edit: make sure to reverse your dis-assembly as you re-assemble your rig. The washer fluid tank, horns, electrical stuff, battery all need to be put back. And make sure to double check that everythings is tight, once your all done, especially with all the fender bolts, grill bolts, etc.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 02:32 AM   #9
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those look sweet!!!
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Old 12-01-2011, 12:28 PM   #10
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Here's a comparison, of the old fenders' spacing between the tire, and the DeFender.

(You can see in the last pic, where I trimmed my nurf bars back. They'll get re-done at a later date. They are homebuilt bars)
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 12:30 PM   #11
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And here's what the TJ looks like, with the DeFenders:
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 03:48 PM   #12
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What is your impression of the fit, finish, and integration with your existing body parts? Do they fit flush? Was any coaxing required?

What is the paint code of your Jeep?
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Old 12-01-2011, 04:33 PM   #13
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Quote:
Originally Posted by erickpl View Post
What is your impression of the fit, finish, and integration with your existing body parts? Do they fit flush? Was any coaxing required?

What is the paint code of your Jeep?
Fit & finish were supurb. It probably took 5 pounds of forward pressure to hold the fender to the grill while securing those bolts. Securing the inner fender to the outer fender took a bottle jack to hold it there, so I could press down with the drill to make the holes. If I had an extra hand, it would have been easy to do without the jack. But I need to hold up to the inner fender, while drilling down from above.

I don't remember the paint code, but it's Emerald Green. And the fenders were painted by 'code', off the body, then installed. So I was very pleased with the color match, on OEM paint that's now 14 years old.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-01-2011, 09:05 PM   #14
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Quote:
Originally Posted by TreeClimber1 View Post
Fit & finish were supurb. It probably took 5 pounds of forward pressure to hold the fender to the grill while securing those bolts. Securing the inner fender to the outer fender took a bottle jack to hold it there, so I could press down with the drill to make the holes. If I had an extra hand, it would have been easy to do without the jack. But I need to hold up to the inner fender, while drilling down from above.

I don't remember the paint code, but it's Emerald Green. And the fenders were painted by 'code', off the body, then installed. So I was very pleased with the color match, on OEM paint that's now 14 years old.
Edit: Check out Eric's TJ. Cracks me up!
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 12-02-2011, 09:15 AM   #15
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Quote:
Originally Posted by TreeClimber1 View Post
Edit: Check out Eric's TJ. Cracks me up!
Your TJ and my TJ are the same paint code. PGF.

Glad you like the chop. You can see the droopy eyebrow on the passenger side. My fender was painted, but the code didn't match quite as nice as I'd like. If I go with DeFenders, I'll just go with black to go with the rockers and corner armor.

Got any pics of where the fenders meet up at the firewall?
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Old 12-02-2011, 12:28 PM   #16
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Quote:
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Your TJ and my TJ are the same paint code. PGF.

Glad you like the chop. You can see the droopy eyebrow on the passenger side. My fender was painted, but the code didn't match quite as nice as I'd like. If I go with DeFenders, I'll just go with black to go with the rockers and corner armor.

Got any pics of where the fenders meet up at the firewall?
Didn't take an closeups of that, but you can click on the pictures in the link, and they'll enlarge, so you can see the existing pics in a larger format.

Black rockers will also look good. I almost went that way myself.
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 06-19-2012, 12:30 PM   #17
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tested:
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1992 YJ, 401 V8, EFI, TH400, Atlas, D60s, Detroits, Warn 8274, Cage, 37 Krawlers
1997 TJ, 350 V8, EFI, TH400, Atlas 4spd, D60s, Detroits, Warn 12000, Cage, 40 Kevlars
TTC 1994, TTC 2012, Trail Tour participant.
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Old 06-19-2012, 03:52 PM   #18
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And how did they hold up? Also how the hell do you manage that? It looks like your jeeps diving down to take hell on!

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