Originally Posted by kbar

Yep... U convinced me... Def doing this as my first mod! I have a garage and just want to do something to my jk!! Let my mod addiction begin!!!

Originally Posted by ebp 99 si

has anyone done it without removing the fenders?
if i just remove the marker light, would it still work and skip some of the steps?

Originally Posted by TheonlyREDhead 2008 JK

Ok I have watched, read, and dreamed about cutting my fenders and I finally did it

Thanks to all those who have posted write ups and pics and answered my many questions

So here is my version very similar to all the rest but I tried many tools and after doing it have some advice for those who want to try it.

So here goes,


First tape them off of coarse










My best friend is an auto body guy so he did alot of the work and gave me advice and we tried several ways to make it work and be easy.


I figured out it is best to remove the under guard first and remove the light socket on the side. So that way you may want to use it for a marker light mod which is what I am working on now.

To remove the under guard first remove the rivets along the edge on the front the easiest way is an air chisel sharped of course



Then pop out all the little plugs that hold it in, BEWARE my buddie had more of these plugs also called xmas trees you need them because they are very easy to ruin or break Here is the tool I used to remove the xmas trees

Here are some extra xmas tree plugs


Here is close up of one, he said they are cheap and you can buy them at any auto body shop


Lay under guard to the side

Then cut fenders I first tried an air grinder first a shallow run to line it then a deep cut to go all the way through.

Here is the air grinder


http://www.youtube.com/watch?v=QHkokWzb67o

Then I tried a sawzall and it worked the best so cut those fenders off, it is best to have someone hold the fender for support so it vibrates less but it could be done alone

http://www.youtube.com/watch?v=WZ_mfzMZ7Zg

Then you have to trim some of the lower hanging brackets that connected the sides

http://www.youtube.com/watch?v=73K5OdjXn_s


Here is the fender cut but without the under guard



Then set under guard back in to see where to cut it, I taped it off and cut it with snips





Here are the snips


Here it is with the under supports trimmed and under guard in



I also put one screw in to hold the side of the under guard in near the back of the wheel well, I drilled through the plastic and metal and drill screwed it in, it made the under guard alot more sturdy



Then sand the edges with 80 grit sand paper on a block and get them a little rounded.





Clean the edges with a solvent

Apply the plastic door trim along the edge then use a heat gun to heat it up and press it against the fenders hold for a few seconds



Ok now to the back fenders mask them with tape





Then use an air chisel to pop the rivets along the side again and pull all the xmas plugs and pull out of the rear under guard and I did not re-install the rear under guards

Cut rear fenders with sawzall,



sand and repeat the steps to apply door trim.




Next I am cutting that bumper!!!!!



I hope this helps.

Here are some finished pics, I figured I can always go skinnier but I can't make them wider again, so maybe I went a little too wide I tried to keep a little of the curve because they are alot stronger that way.











I am happy

Red

p.s. I also trimmed a small corner of the front scoop below the bumper cause my 35's where rubbing at full turn in reverse.



**** I have since added some super glue to places on the door trim on the fenders where mud had pushed it down, now it stays up and looks great!





Ok what do you all think of the write up?

And what do you think of the work?

Originally Posted by ebp 99 si

has anyone done it without removing the fenders?
if i just remove the marker light, would it still work and skip some of the steps?

Originally Posted by otnman

For those that have done this. Is there room to use the same lines but deviate and cut around the light and it still have a place to attach in the stock location? I;m not sure how it would look though.
otnman

Originally Posted by M_anstrom

That looks sick, Way better than shelling out the $369 for the aftermarket fenders that look like that. Seems I have a project for when I get back from my deployment .

Originally Posted by kbar

Yep... U convinced me... Def doing this as my first mod! I have a garage and just want to do something to my jk!! Let my mod addiction begin!!!

Originally Posted by FFA_nsk

I did this today. I didn't feel like bed lining the interior yet so I borrow a sawsall and drimmel from a friend. It took like 20 dollars and 3 hours. Worst pay was getting the plastic wheel well crap out. I hate whoever invented those Xmas tree things . They all got destroyed . Only problem is I can't find this plastic door trim . What exactly is it

Originally Posted by FFA_nsk

I did this today. I didn't feel like bed lining the interior yet so I borrow a sawsall and drimmel from a friend. It took like 20 dollars and 3 hours. Worst pay was getting the plastic wheel well crap out. I hate whoever invented those Xmas tree things . They all got destroyed . Only problem is I can't find this plastic door trim . What exactly is it