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Old 10-05-2013, 04:33 PM   #1
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Crushable fender flare idea, comments please....

Ok , first of all I am a hunter, my Jeeps sole purpose if for hunting. I only hit the ground, I dont hit vertical things on purpose like some people. So I know this idea is not for the rock crawler crowd. I have 6 inch plastic flares on my Jeep now and cant stand the looks of them. I did glance a tree and popped out a hole in the front drivers side flare many years ago. My idea is for the aggressive looks of tube fenders but not the price and still have average user durabilty is this....

3/4 emt conduit frames welded to flat bar then bolted to the jeep sheet metal in similar shape to the plastic flares. On the emt skeletons have flashing pop riveted every couple of inches. The emt could be run rounded or sharper transitions to the user liking. I like the straight lines more ( the reason I dont like the rounded flares thats on it now) . Anyhow 3/4 emt conduit is soft enough to crush before transmitting to much body damage I would think.( the flashing is also soft). The flashing I am thinking will show rock dings fairly fast from high speed dirt road use. At least my tires like to pitch rocks after leaving the trails. But things would be easy to fix as needed. I have had great results welding emt conduit before ( duck blinds)(aquaponic frame above my aquarium). I was a pipe fitter/ welder for 16 years and yes you do not want to huff galvanizing fumes very long.
This idea has been eating me up. The conduit is cheap, flat bar is cheap( dont buy from big box hardware shop) rivets not bad, flashing not bad. Notching and rewelding the emt to get angles will suck time. Then getting things to match side to side might be rough also, but doable. Small bolts can be bought by the pound at my local farm supply. I think the end result will be strong enough to handle brush and what not, things kicked up when off trail(someone stuck in front , new road to get around them type stuff). No they wont take rock rash, rollovers that type stuff, but if it did happen they would crush and save body damage I hope. The wife may have to park outside for a while sounds like the garage is going to have a project in it.

What do you think?????
Remember one mans ugly is another mans $1000+ dollars still in his bank account( just thought I would say that knowing someone will say those things will be hideous looking) I plan on going full camo anyway, just finished the top a couple of days ago.[IMG][/IMG]

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Old 10-05-2013, 06:25 PM   #2
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what's wrong with the way your jeep looks?

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Old 10-05-2013, 06:48 PM   #3
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If it's all cheap then go for it. Worst case you can fab up a couple of runs to see how well they work. You could have a million dollar idea there.
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Old 10-05-2013, 10:34 PM   #4
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The easiest way to may your Jeep look better in a photo is to put a girl in it. Preferabliy in a bikini!!!!!!
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Old 10-06-2013, 04:12 AM   #5
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Get some krylon fusion spray paint in satin black and paint the flares. Will make a world of difference.
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Old 10-06-2013, 10:23 AM   #6
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if you are a welder you can build your own flat fenders that will add to the looks of your jeep rather than taking away from it. It does not cost much in materials
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Old 10-06-2013, 10:46 AM   #7
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I would like to see how it looks with the full cammo before you toss the fenders. Unless, of course, you are just looking for a project. Top looks great and I bet the fenders will almost disappear anyway when the body is painted. Either way it would be cool if you posted pics after it's done.
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Old 10-06-2013, 10:55 AM   #8
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I think the plan should work out just fine for your purposes, but as Harley Dragon said you have the tools and skills to build real tube fenders. Then you won't have to worry about rebuilding after they get too dented up, you can build them strong enough so they don't bend in the first place.
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Old 10-06-2013, 02:42 PM   #9
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Check this out:

Post #11:
tube fenders
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Old 10-07-2013, 11:31 PM   #10
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I am thinking weight also

The buckshot500 fenders are similar to what I am thinking but with a flatbar mounting sutface for the body sheet metal. Basically like the plastic flares are mounted. The are so many pros and cons. I was thinking cheap, even the diy kits are you get someone else's idea what the lines of the flair should be. My plastic flares are bound to be getting brittle( ones allready has a tree boo boo) . Cold weather and plastic just dont get along. Also full corner gaurds and heavy tube flares would be like having two people with you all the time. More gas, more sinking in the gooey stuff.
Thinking of keeping bumpers and wheels black. Making the emt flares and doing them in black and camo the rest. Full camo dont look right to me. I am not really going to put a sun roof in and drive it to the lake and duck hunt from it like I told my wife( she was not amused). Or kaki desset tan, black wheels? Anyhow the emt flares are a go, will be gathering stuff inbetween deer and duck hunting. Im not good at keeping up with photos but will try to get basic points as I go. Gasless flux cored wire, yea the welds will be " reeel purtty lookin ".
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Old 11-14-2013, 09:38 PM   #11
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Got'em done!

Got everything done except for trimming along the flat bar on the inside of rear wheel well. I added two led side markers to the front to keep DOT happy. The flat bar was 35 cents a foot. 1/2 inch emt conduit 1.89 for 10 feet. Flashing was 10 bucks for 10" x 10' ( used roll and half). The side markers were 12 bucks.
The rustoleum spray on bed liner was 8 bucks a can but has a good finish, used 3 cans. Primer was 4 bucks used one can( had a couple of partial cans). Bought 2 boxes pop rivets and washers around 12 bucks.

Anyhow I know that the paint wont hold to the galvanizing for long, but a can of cheap flat black primer will be kept close. If I would have reused the old side marker lights and just used flat black primer I could have done this thing cheap. Oh yea,welding wire (15 bucks gas-less ) , time and electric !!!. Its done now and looks pretty good. The frames are really stiff, the flashing is tinny sounding but will be real easy to fix. I really did not like the look of my store bought flares due to the axle swap put my wheels way wider in the front. Now the flares cover just to the edge of the widest lug. The sidewalls are not covered, so maybe I can escape a light rub against a tree without hitting the flares. The front and back are equally covered, not one end sticking out and the other tucked way under. Yea I know someone will say it looks funny with a wide flare up front and skinny in the back, all well its done.
I will try to post photos next . I tried to take plenty along the way through this project.
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Old 11-14-2013, 09:41 PM   #12
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Before

[IMG][/IMG]
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Old 11-14-2013, 09:43 PM   #13
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After

[IMG][/IMG]
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Old 11-14-2013, 09:45 PM   #14
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side markers

[IMG][/IMG]
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Old 11-14-2013, 09:47 PM   #15
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Side marker

The lights have 1/8 inch flat bar under them,and welded to the conduit at the top and front. I figured rocks would get them under the fender so I went heavy duty
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Old 11-14-2013, 09:50 PM   #16
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more crushable flare picts

[IMG][/IMG][IMG][/IMG]
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Old 11-14-2013, 09:53 PM   #17
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Yes welding galvanized sucks

[IMG][/IMG][IMG][/IMG]
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Old 11-14-2013, 09:59 PM   #18
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[IMG][/IMG][IMG][/IMG]
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Old 11-14-2013, 10:01 PM   #19
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more picts( kinda random sorry)

[IMG][/IMG][IMG][/IMG]
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Old 11-14-2013, 10:06 PM   #20
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still finding picts

[IMG][/IMG][IMG][/IMG] Homemade bevel gauge, hacksaw blade broke in half. I am so cheap...
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Old 11-14-2013, 10:09 PM   #21
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[IMG][/IMG][IMG][/IMG]
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Old 11-14-2013, 10:17 PM   #22
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lines were off at bends on the top( all well)

[IMG][/IMG]
Hard to make one piece bend at two points and keep a straight line on one side, should have over lapped both sides and trimmed instead of trying to get two pieces from one. Next time...[IMG][/IMG] The front one ,ended up with a small lip at the top also. Live and learn......
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Old 11-14-2013, 10:22 PM   #23
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weight difference

Forgot to weigh the front flares against the after market plastics. I did weigh the back ones and only gained around a pound each. My take offs were really thick plastic. Not sure on the front ,should have been about the same gain?
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Old 11-14-2013, 10:54 PM   #24
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The crushable flare idea is a reality at last.

I hope if I ever do hit something hard the flares collapse like I planned. The frames ended up a little more rigid than planned, but the conduit is still soft enough to give I hope. The 1/8 flat bar should help protect the body from the inward motion of the conduit, and also the galvanizing in the welds should help give also. The flashing will give no matter what.
I like what I have done on the first try. I could have redone the lines at the tops to get rid of the ear or pucker or lip or whatever you want to call it, but this is a trial. Ill fix that later if I have to re-skin them. The Led side markers came out ok also. I looked for the 3/4 inch round led , but couldnt find them locally. Also I used camper seal between the flares and body. That was another 10 bucks I think. Over all, I achieved what I was after( matching flare width to tire front and back). Straight lines instead of the round rear flare( that one always ate my lunch, dont know why???) Got a more aggressive overall look( to me anyway ). Now time will tell on durability, or surprise issues that may arise. I think I will leave what body is showing on the front( paint it black). The rear I will cut out to match the flare. Then tackle the camo paint job on the rest of the Jeep.



I think I will leave the flares black( I know I will be constantly touching them up with the galvanizing being under the paint). The rocker guards , and bumpers black, since I have mostly black wheels,(and tires ). everything else is going to match the top. I will have to wait till warmer weather, this spring or early summer. Oh man that type of paint job really sucks. Taping off every color a inch or two each direction gets old fast. I think she will pop when done though.

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