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Old 08-13-2013, 06:31 AM   #1
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Cutting fenders

Hey so I've been very unhappy with the look of my YJ lately. A while back I picked up a set of xenon 6" flat flares which i loved. Until I picked up a smittybilt stubby stinger bumper. Now between the stubby bumper, the bulky YJ fenders and the 6" flares it looks like my jeep has wings. I was going to purchase tube fenders but figured I would try and go the cheaper route by cutting my stock fenders. I'm a little nervous about this. Just wondering how u guys went about doing this. Any advice would be greatly appreciated

My jeep


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I kinda like what this guy did



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Old 08-13-2013, 06:42 AM   #2
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I did tube fenders, no matter if you cut or do the full tubes, they both have one huge thing in common. The first cut is the hardest thing you will do to your Jeep, that first irreversible cut is the hardest thing to do, no question. Just rest assured that new fenders are cheap (though unpainted) so no matter how bad it ends up you can always start over or go to tubes. That being said, it's always easier to trim a little further than glue metal back on, so cut a little short of where you think you should, especially when trying to match up the other side. Good luck and have fun, it really isnt so bad after that first cut.

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Old 08-13-2013, 07:24 AM   #3
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yeah,those you pictured that had been cut looked good to me.I think yours would look a lot better if you just removed the flairs.one thing to think about is,when you cut the fenders it usually weakens them
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Old 08-13-2013, 07:48 AM   #4
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yeah i was scared to drill my first hole in the hood when mounting the light bar lol... first cut is definitely the hardest, but its happening lol. and i plan on doing tube fenders eventually up front (gonna do a 3" tube flare in the rear). ive gone flareless between the OEMs and flats and i didnt like the way it looked with all the holes etc. i want to cut them and give them a finished edge with a black rubber trim
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Old 08-13-2013, 07:54 AM   #5
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do you have any state laws requiring you to cover tires that extend past the fenders?
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Old 08-13-2013, 09:25 AM   #6
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I trimmed mine because I'm not buying new fenders until I can afford metalcloaks. I've got the same bumper as you and I think flat/tube style is the only way to go. Especially when the only thing it costs you is a little time... I left about an inch on the outside of mine because the bend in them helps a little with the strength. I also left the 3-4" wide support brace under it and remove the long ~1/4" diameter support that was towards the front. I sit on mine while I'm working under the hood. If they bend a little, I just bend em back but they're still sturdy.


Here you can see the brace that I left and since I'm not using the long oem side marker (but I could mount it back to the fenders) so I got a small LED for each side.
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Old 08-13-2013, 09:29 AM   #7
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do you have any state laws requiring you to cover tires that extend past the fenders?

yes, but im not worried about that


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I trimmed mine because I'm not buying new fenders until I can afford metalcloaks. I've got the same bumper as you and I think flat/tube style is the only way to go. Especially when the only thing it costs you is a little time...

nice, i was thinking about not leaving that edge that come down towards the ground. any advice about cutting it?
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Old 08-13-2013, 09:34 AM   #8
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yes, but im not worried about that

nice, i was thinking about not leaving that edge that come down towards the ground. any advice about cutting it?
Just tape off what you want and jump in basically. I edited my post and added another shot from below the fender. I removed those 3 bolts that mount the fenders to the radiator support towards the front. That allows you to pull the fenders away from the rad about an inch or two so you can cut down the front without cutting into your grill. Other than that, once you start it's not so hard.
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Old 08-13-2013, 09:40 AM   #9
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I was also going to cut the whole edge off as well, but I've seen a couple of rigs that are like that, and it just makes it look really really thin.
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Old 08-13-2013, 09:43 AM   #10
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ok cool, yeah i was nervous about where it meets the grille. i think im gonna tape most of the fender and draw a guide line and undercut it so i can shape it the way i want. i like the side marker you added in the wheelwell
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Old 08-13-2013, 09:51 AM   #11
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Yeah I wedged something in between the fender and grill to hold it out while I cut down. Thanks, I got the LEDs from amazon for like $7 I think? They're really bright and perfectly visible.
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Old 08-13-2013, 10:10 AM   #12
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O M Jeep is 100% correct. The first cut is the hardest, after you make the first hole in the sheet metal the rest is cake. I still get nervous before the first cut when I decide to chop more off my Jeep, but after I get started it's nothing. I've cut a lot off, I have no fenders anymore, just starting to make my own version of metalcloaks now. We'll see how they turn out. Use a 4 1/2 inch angle grinder with a cutoff wheel and go to town.

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Old 08-13-2013, 10:14 AM   #13
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O M Jeep is 100% correct. The first cut is the hardest, after you make the first hole in the sheet metal the rest is cake. I still get nervous before the first cut when I decide to chop more off my Jeep, but after I get started it's nothing. I've cut a lot off, I have no fenders anymore, just starting to make my own version of metalcloaks now. We'll see how they turn out. Use a 4 1/2 inch angle grinder with a cutoff wheel and go to town.

thanks.... im not sure if i'll get to it this week or not... my To Do List is pretty long lol but it will get done very soon
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Old 08-13-2013, 10:41 AM   #14
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Hey no problem, and trust me I know how it is, my 'laundry' list of things to do on mine is quite long as well.

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