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What tool to use to cut Jeep TJ Fender

  • Jigsaw

    Votes: 4 21.1%
  • Sawzall

    Votes: 1 5.3%
  • Angle Grinder

    Votes: 9 47.4%
  • Air Nibbler

    Votes: 3 15.8%
  • Bacon

    Votes: 6 31.6%
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Discussion Starter · #1 ·
Okay, so by searching I've got: body saw, air nibbler, angle grinder, plasma (no way I can afford one with my other mods going on), jigsaw, and sawzall (don't see how clean this would be lol). Basically I'm looking for a tool that cuts the cleanest. Tell me which tool you used or what you think would be the best and why? Thanks forum!
 

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Not listed and at the time it was a "have to thing"...I used a Dremel with a tiny little cut off wheel....IIRC it was about 3 wheels per side.
I cut the lower portion of the front of the fender "free hand". to "hide" a bent fender that had damage and bondo, before I painted them black...old Pic.
 

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Discussion Starter · #5 ·
Not listed and at the time it was a "have to thing"...I used a Dremel with a tiny little cut off wheel....IIRC it was about 3 wheels per side.
I cut the lower portion of the front of the fender "free hand". to "hide" a bent fender that had damage and bondo, before I painted them black...old Pic.
That's a neat little mod that I would probably have done if I didn't plan on cutting the whole thing off :thumb:
How long did it take the cutoff wheels to cut that small section?
 

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That's a neat little mod that I would probably have done if I didn't plan on cutting the whole thing off :thumb:
How long did it take the cutoff wheels to cut that small section?
It wasn't really that bad.....I spent a Sat morning figuring out how I was going to hide the bent fender/ pulling it "straight" (by hand)/ filling it with bondo/ cutting each side/ and painting it. All told with trips to the store about 3 or 4 hours....probably 15-20 minutes per side. actual cutting.
 

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Discussion Starter · #7 ·
It wasn't really that bad.....I spent a Sat morning figuring out how I was going to hide the bent fender/ pulling it "straight" (by hand)/ filling it with bondo/ cutting each side/ and painting it. All told with trips to the store about 3 or 4 hours....probably 15-20 minutes per side. actual cutting.
That's not too bad!
 

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I used a drill bit everywhere my cut need to make a turn then I just used a sawzall to cut from drilled hole to hole. It worked great and was fast.
 

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im using a cutoff wheel, my tubes should arrive tomorrow
 

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I've cut my fenders off on both of my TJs and had the best results with my jigsaw and a fine pitch metal blade. That was after using an angle grinder which worked but was a little harder to make straight cuts with. But then I didn't have to worry about an especially clean cut since the cuts were covered by the new fenders. I use my Dremel tool all the time but I wouldn't use it this much cutting.

 

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Discussion Starter · #15 ·
I've cut my fenders off on both of my TJs and had the best results with my jigsaw and a fine pitch metal blade. That was after using an angle grinder which worked but was a little harder to make straight cuts with. But then I didn't have to worry about an especially clean cut since the cuts were covered by the new fenders. I use my Dremel tool all the time but I wouldn't use it this much cutting.

Thanks for the advice Jerry! I swear I can't look up a mod on here or JF without seeing your name :dance:
 

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I will be cutting mine today, I am good with a angle grinder / cut all my metal/ fabrication work with one, so I will be using one on my fenders as well. Gonna rig up some custom square tube fenders that go down to meet my rockers ( which are custom tube as well )
 

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I used a 4 inch angle grinder with a cut off wheel for my fenders. I used a jig saw for my hood louver install.

I don't think the jig would have cut through the double weld seam on the top of the fender. It would be difficult for the down cut with a jig as well.
 

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Bacon. Because bacon.
 
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