To fender chop or not to fender chop

Doknocker said:
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This is what I used. I went through 4 discs on the first flare, then I figured out how to do it right and didn't break any more disc. These disc also don't shatter like the small ones.

You definitely need eye and ear protection. Hot plastic tends to come flying out.

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This wood rasp is also a great tool to even out your cut if you don't intend to use edging. And the finishing tool is a vibratory sander for making a nice smooth edge.

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X2. I didn't use a rasp but just a utility knife and just a block with fine sandpaper on it, but same concept.
 
DallasJKU said:
Thinking about doing mine and this is same size tire I have. I want to go with 37's and I would have to chop for sure, but I want to stay around the 2.5" lift. Is that possible??
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I am running bushwackers, and was on a 2.5 lift with 37s and never had issues with rubbing, well something rubbed ever so slightly but havnt had the chance to track it down. Im now on 3" coils tho, and plan to go to stock cut flares tho.
 
hinrichs said:
I am running bushwackers, and was on a 2.5 lift with 37s and never had issues with rubbing, well something rubbed ever so slightly but havnt had the chance to track it down. Im now on 3" coils tho, and plan to go to stock cut flares tho.
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Guys, I've chopped 3 sets of flares in the last 4 months or so. The tool to use is a small air reciprocating saw. The first time took me about 2hrs, the last set took me about 45mins. Air saw it, clean the edges with a file/ rasp and apply self stick door trim from auto parts store. I masked it off with painters tape for exactly where I wanted to cut and the air saw literally cuts the fender in about 2 mins. 30 sec on the front splash guards remove the rears and paint the wells with spray on bedliner and you're all good. Oh and relocate the side marker lights or replace with cool little led lights like my Texas/ Conn/ Georgia buddy JethroJK has from OReilly Autoparts.
 
Just did mine yesturday second jeep I did it to. I'm running 35's on 3 inches of lift I thought about it since buying the jeep in april I still like the look after doing it.....
 

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Been wanting to share this. My son-in-law wanted to cut his fenders and at first we could not agree. I wanted him to leave them full width and he was going for half. I won. You can always go narrower but you can't go wider. I used a sonic crafter for all and it worked great. Followed the contour of the grill, got up on top and made a radius to the side. Now for the important part, we live in the Midwest and snow and salt happen. So my reason to keep them wide. Instead of cutting the inner liner flush with the body, I took a heat gun and rolled it back to cover the gap. It took a few calculated cuts and it all came back together. After we trimmed the top support we then glued the fender down with black polyurethane roofing cement so they wouldn't flutter in the wind and get ripped off or ice and snow damage. Hope this helps.

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I chopped my painted fenders after I got my 35's and was rubbing them every time we went out to wheel. I don't regret it one bit and I like the way it looks. I used a jig saw and a fine tooth blade made for cutting plastics.
Me and josh.jpg
 
olram30 said:
how do you like those smitty doors?
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They are stout doors for sure just wish they sold some types of skins for them so I can keep some of the wind, mud, and water from coming in all the time. I found a write up on somebody who made some skins and I think I am going to take a crack at it.
 
As wittysjk said the jigsaw is the way to go. I have done 3 sets so far. I was able to keep both front and rear inner fenders as well. First pic is my 07 and the rest are of my new rig. ImageUploadedByWAYALIFE1383259167.843352.jpgImageUploadedByWAYALIFE1383259257.756991.jpgImageUploadedByWAYALIFE1383259281.273230.jpgImageUploadedByWAYALIFE1383259316.608333.jpgImageUploadedByWAYALIFE1383259342.974473.jpg
 
DallasJKU said:
I'm running 315's right now with 2.5" AEV which netted me slightly over 3". With new used soft top I'm not sure I can fit 37's into my garage with more lift. I was thinking of just chopping and then stuffing 37's and adding a 1" BL if necessary.
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I'm running 2.5" lift and 35's. Chopped my fenders and looks good. Also Hinrich was running the same lift as me and stuffed 37's under his bushwacker fenders. Here is a pic of his rig

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Best part is he never rubbed with that set up.


Sent from my iPhone
 
DallasJKU said:
I'm running 315's right now with 2.5" AEV which netted me slightly over 3". With new used soft top I'm not sure I can fit 37's into my garage with more lift. I was thinking of just chopping and then stuffing 37's and adding a 1" BL if necessary.
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You can fit them under a 2.5" just need to trim a few things and play with some bump stops.
 
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