How To Install Bushwacker Fender Flares On Jeep Xj
As we started to build up our 1997 Jeep XJ Cherokee, ane of the things nosotros wanted to do was run as big of a tire every bit nosotros could and with as little of lift equally possible. And, afterward doing some inquiry, we decided to try running a gear up of 285/70R17 Nitto Trail Grapplers which take a true measurement that's just shy of an advertised 35x12.50R17 and run them with just a 2.v" Rancho lift kit. Of course, this wouldn't be remotely possible without doing some kind of trimming of the trunk and, that's why we picked up a set of Bushwacker Flat Fenders.
Having installed a fix of Bushwacker Flat Fenders on our old 2009 Jeep JK Wrangler in the past, I knew they would look manufacturing plant when finished, would be calorie-free weight, would offer a lot more clearance nether the wheel well and would also exist durable. Once I realized simply how much I would demand to trim to get them installed, I knew these would be perfect for our needs. The below is an installation write-up on how to install these flat fenders on a 1997-01 XJ and I point that out because there are a few things you will have to do differently on an earlier model XJ. As well, I should point out that this write-up should exist used equally a compliment to the instructions provided by Bushwacker.
What y'all will need
• Utility Knife
• #2 Phillips Drive Bit
• Electric Drill
• 1/4" & vii/64" Drill Bits
• #2 Phillips Screwdriver
• Socket Wrench
• 1/4" Socket
• 7mm, 8mm & 10mm Sockets
• Scratch Awl
• Angle Grinder
• Soft Wiping Cloth/Store Towels
• Pry bar/Hook Hammer
• Safety Glasses
• Grease Pencil/Marker
• Partner/Helper
• Putty Pocketknife/Molding Remover
Here's a shot of everything you lot will go with your new Bushwacker Jeep XJ Flat Fenders.
Instructions
1. The plastic factory fender flares are attached to metal brackets that are bolted to the body (photograph just shown with the subclass). Using a 10mm wrench, remove the 7 nuts securing the subclass and pull the entire fender off the torso of your Jeep.
2. Remove the fender liners from cycle wells using a pry tool or flat head screw commuter. There are a total of 7 tabs that will need to be pulled in order to remove the liner.
3. Clean the body panels around the bike well with rubbing alcohol and a clean rag.
iv. Mensurate iii-three/iv" from the frontward border of the body console dorsum toward the fender well and and then draw a small-scale vertical line with a grease pencil.
v. Starting on the passenger side of your Jeep, find the plastic inner structure pieces with P1 and P2 stamped into the mold.
half-dozen. Place the P1 slice up against the fender then that the 2 rear holes line up with the existing mounting holes on your Jeep. Use two of the washers, M5-.8 machine screws and flange nuts provided to loosely secure the P1 piece on to these 2 holes.
7. Position the P1 piece and so that it lines up with the mark you made on the body console dorsum in Footstep 4. So, use the P1 as a template to marker the position of the front hole with a grease pencil.
8. Remove the P1 piece and then center punch the marker you just fabricated.
9. Use a unibit or 1/iv" scrap to drill a hole at the point you just marked.
ten. Reinstall the P1 piece and secure it in place using the washers, M5-.eight car screws and flange basics provided. Get out the bolts and nuts only mitt tight for now.
11. Measure out iv-one/2" from the door edge seam, along your Jeep'south style line and and then make a marker with a grease pencil.
12. Mensurate half dozen-i/eight" from the door edge seam, along the lower of the 2 parallel style line then make a marking with a grease pencil.
13. Place the P2 slice upwardly against the fender so that the frontwards nearly hole on it line up with the existing mounting hole on your Jeep. Employ a washer, M5-.8 auto screw and flange nut to loosely secure information technology in place. And then, position the piece so that it lines up with the 2 marks y'all made on the body panel back in Steps 11 & 12. Using the P2 every bit a template, marking the position of the rear holes with a grease pencil.
xiv. Remove the P2 piece, center punch the marks yous just made and then drill them out to 1/four" holes.
15. Reinstall the P2 piece and secure it in place using the washers, M5-.viii machine screws and flange nuts provided. Leave the bolts and basics only paw tight for at present.
16. Using the installed P1 and P2 pieces as a template, trace the inner contour of them with a grease pencil every bit shown.
17. Continue the contour line down to the bottom in a parallel line to the fender well.
18. Remove P1 and P2 nevertheless again and and then describe parallel lines ane-1/2" apart and perpendicular to the profile line you lot drew forth the rear half of your bicycle well as shown.
xix. Being that I will be using a jigsaw to trim the fender, I took some time to trace the outer border of the profile line with some bluish painters tape. This volition help prevent the jigsaw from damaging the paint as information technology passes over the body while cutting the metallic.
xx. Using a jigsaw with a metal cutting blade or a cut off bike, brainstorm trimming the trunk along the profile line.
21. Using a jigsaw with a metal cutting bract or a cut off wheel, begin cutting the body along the parallel lines you fabricated on Step #18. Be careful to NOT cut past the profile line.
22. Utilize a pair of pliers to fold back the 1-1/ii" tabs.
23. Apply a hammer to pound the ane-ane/two" tabs flat as shown.
24. Utilize a sawzall to cut off the remaining metallic along the pinch seam.
25. Use a sawzall or bending grinder to cut a serial of notches along the inner pinch seam as shown.
26. Use a iii lb. Hammer to pound the inner pinch seam flat as shown.
27. Install the provided speed clips over the 6 predrilled holes located forth the edge of the P1 and P2 pieces.
28. Reinstall the P1 and P2 slice onto the trunk of your Jeep and secure them in place using the washers, M5-.viii automobile screws and flange nuts provided. Fully tighten the bolts and nuts using a five/16" socket and wrench. Use a #2 Phillips scrap for the M5-.8 screws.
29. Take your new Bushwacker passenger side front fender and install the c-channel side of the edge trim along the upper edge. Go out the blood-red tap on the other side in place.
30. Thoroughly make clean the surface of your Jeep's body panel where the fender will be mounted with some rubbing alcohol. Then, peel back 1"-2" of the red tap on the edge trim so that you volition have something to grab onto and then install the Bushwacker flat fender onto the P1 and P2 inner structure pieces. Use a scratch awl to help align the holes on the bottom of the fenders with the speed clips on the inner structure pieces.
31. Pushing firmly against the side of the fender, secure the bottom of it in identify by installing #8 pan head screws into each of the 6 holes.
32. Push lightly downwardly on the fender while peeling the red tape out as shown.
33. Insert the border trim tool provided with the kit between the lip of the border trim and the fender and firmly slide it along the entire length of it while pushing the fender toward the body of your Jeep.
34. Moving to the rear of the Jeep, trace the style line forth the wheel well with a grease pencil or some blue painters tape. Once more, existence that I'm using a jig saw to brand my cuts, the blue painters tape will aid prevent whatever impairment to the paint while trimming. Make sure that all the factory mounting holes will Non get cut. The large hole that dips downwards into the fender well will be cutting in half.
35. Use a jigsaw or cutoff wheel to trim the fender well.
36. Using a grease pencil, draw a couple of lines 3/8" away from the door seam.
37. Find the plastic inner construction pieces with P3 and P4 stamped into the mold.
38. Place the P3 piece upwardly against the forepart of fender and so that the 2 holes line up with the existing mounting holes on your Jeep. Use 2 of the washers, M5-.8 machine screws and flange nuts provided to loosely secure the P3 slice on to these 2 holes.
39. Position the P3 slice so that it lines upwards with the marks yous made on the torso panel dorsum in Step #36. And so, utilise the P3 as a template to marking the position of the front lower hole with a grease pencil. Use a scratch awl to marker the upper pigsty.
40. Identify the P4 slice up against the rear of the fender and then that the superlative hole lines up with the existing mounting hole on your Jeep. Use a washer, M5-.8 machine spiral and flange nut provided to loosely secure the P4 piece onto the pigsty.
41. The Bushwacker instructions provided steps to prove where marks should be made to help position the rear P4 piece. Because I was unable to remove my rear bumper end cap at the time of installation, I just fabricated an educated guess every bit to where the P4 piece needed to be in regards to the fashion lines on the Jeep. Once in position, use a scratch awl to marking the two holes.
42. Belongings P3 and P4 in place and using them as a template, trace the inside profile of them with a grease pencil.
43. Remove P3 and P4 and then, drill 7/64" holes through the body on the upper 2 marked spots. Drill 1/4" holes through the lower ii marked spots.
44. Starting from about iii" above the upper style line, depict 1-1/two" parallel lines extending out from the profile line you drew in Step #39 and downwardly toward the compression seam.
45. Again, starting from about 3" higher up the upper style line, draw one-1/2" parallel lines extending out from the profile line you drew on the rear half of the wheel well and down toward the pinch seam.
46. Using a sawzall with a metallic cutting blade or cutoff wheel, trim the rear fender well forth the profile line you drew down to the offset parallel line you lot drew in Steps #44 and #45
47. Using a jigsaw with a metal cutting blade or a cut off wheel, brainstorm cut the trunk along the parallel lines yous made beingness conscientious to Non cut past the profile line.
48. Use a pair of pliers to bend back the parallel tabs.
49. Use a hammer to pound the ane-1/two" tabs apartment as shown.
50. Reinstall P3 and P4 using the hardware provided and go along to install the Bushwacker flat fenders in the same mode every bit you did up front end. Then, echo all the steps on the driver side of your Jeep.
Hither are some shots of what everything should look like when all is said and washed.
Close up shot...
Source: https://www.wayalife.com/threads/bushwacker-jeep-xj-cherokee-flat-fender-installation-write-up.24919/
Posted by: futrelltwithe.blogspot.com
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