Fender Cut / Rhinoliner Application *PICS*

BooKilla · 06-17-08, 02:24 AM

I was gonna put this in the hardcore section, but I thought about it and the 80 section seemed like the right place. Let me know if it needs to be moved...

There has been a craze recently for rigs to stay low when rock crawling and for good reason. So with that in mind, I started thinking about how I wanted to set up the current project 80 I have. A fender cut seemed like a reasonable place to start. This enables me to gain more axle articulation while keeping my center of gravity fairly low. This is very important considering the size and weight of the 80 series.

This is the vehicle we started with...
First we took the fender off that we were gonna draw the cutting pattern on. We had already taken the fender flares off, which you will need to do.

BooKilla · 06-17-08, 02:36 AM

Next, I decided the line that I wanted to cut. I used a pencil and did it by free hand. It turned out pretty well. I just took my thumb and led it along the edge of the fender well and made a 3 inch line all the way around. I realized that this was not going to give me enough space where I needed it most....

BooKilla · 06-17-08, 02:48 AM

....so I extended the line at the top so it reached 4 inches. This meant it doesn't have the same curve as stock but as the truck goes higher, the front axle is pushed farther back and this will give it the space where is it needed.

The first photo is showing Dave using a nibbler to cut the lines I have drawn. The next one shows the lines I had originally cut on my inner fender well. My thoughts were to bend the tabs from the fender well up and put pieces in between them and weld it up.

BooKilla · 06-17-08, 03:01 AM

I cut the amount I need to off of each tab to make it fit the new fender. This took a bit of time because I to put the fender on and take it off each time to ensure a tight fit.

Then I decided I wanted to cut out a section of steel to make a new inner well all together. So I got out my 6X4 foot section of 1/16 mild steel sheet....doesn't everyone have one of those lying around?

BooKilla · 06-17-08, 03:13 AM

But before I made the inner wells, I needed to reinforce the edge of the fender so I cut out a 3 inch strip to fit it. I used the excess piece I cut off the fender to get the pattern from, put duct tape along the edge and drew the line. I then placed the pattern on the steel sheet and plasma cut the piece. Then TIG tacked it on.

BooKilla · 06-17-08, 03:27 AM

Now be careful when cutting your inner fender well tabs because I sliced the washer fluid bladder and dumped fluid everywhere.

Finished TIG welding the rest of the fender edge and then made the inner fender well. I don't have any photos of the piece I cut out but all you need to do is use the same line from the fender cut out and then spread it out about 6 inches in width. Cut it out and tack weld is to the edge you've cut out on the fender well. We MIG welded the rest, but it could be TIG welded with some more effort.

I also took the opportunity to TIG up holes around the cruiser I would be rhinolining.

BooKilla · 06-17-08, 03:38 AM

These are the lines I choose for my rhinolining. I kept it pretty high on the sides because I wheel with a lot of brush and they scratch up paint pretty well.

Thats all for now, but I am installing ARB lockers f&r this week and we just got a slee lift kit in for this rig at our shop. This summer's gonna be fun!

Boone

fjfar80 · 06-17-08, 03:47 AM

That is a lot of work...but, it looks great and I am sure that it will function really well. Great job and innovative.

thestallionq8 · 06-17-08, 03:52 AM

Looking good! Would like to see the final result!

jfz80 · 06-17-08, 07:16 AM

cool project!!! looking foward to seeing it buttoned up after the lift. Have you checked out bjowett's write up on the rear trimming? LOOKS GOOD.

1shot1kill · 06-17-08, 09:06 AM

Nice!

Izeloz · 06-17-08, 11:00 AM

Do you have an overall shot from the side to show how much you took out and how it looks?

BooKilla · 06-17-08, 11:28 AM

I am headed to the shop later today....I will take some more pics. When you're working it is hard to remember to take pictures.

CreeperSleeper · 06-17-08, 01:00 PM

Looks killer, Boone! Let's go wheelin!

BooKilla · 06-17-08, 01:23 PM

Quote:

Originally Posted by CreeperSleeper

Looks killer, Boone! Let's go wheelin!

Oh yeah....we cascade cruisers have a big summer of wheelin' ahead of us....

Dusty · 06-17-08, 02:18 PM

thanks. real helpfull. I am doing similar right now to front end except I am cutttting out the radiator support on the sides also. more pics please.

so how big of a tire are you going for?

Clarkie · 06-17-08, 06:43 PM

nice job, should be able to get some big rubber under there now!

BooKilla · 06-18-08, 05:31 AM

I will post some more pics soon. I must have sleep...I just spent two hours (from 1am-3am) replacing my alternator which just died on me. I am running on empty...

....and still checking mud at 4:31am

lenross1 · 06-22-08, 06:13 PM

wow

always wondered what it would take to cut the fenders, now i know. you are braver than i am !

96Cruiser13 · 06-22-08, 07:07 PM

i want that lift in my garage! hha

looks great on the white

06-17-08, 02:24 AM	#1
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	Fender Cut / Rhinoliner Application PICS I was gonna put this in the hardcore section, but I thought about it and the 80 section seemed like the right place. Let me know if it needs to be moved... There has been a craze recently for rigs to stay low when rock crawling and for good reason. So with that in mind, I started thinking about how I wanted to set up the current project 80 I have. A fender cut seemed like a reasonable place to start. This enables me to gain more axle articulation while keeping my center of gravity fairly low. This is very important considering the size and weight of the 80 series. This is the vehicle we started with... First we took the fender off that we were gonna draw the cutting pattern on. We had already taken the fender flares off, which you will need to do. Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 02:36 AM	#2
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	Next, I decided the line that I wanted to cut. I used a pencil and did it by free hand. It turned out pretty well. I just took my thumb and led it along the edge of the fender well and made a 3 inch line all the way around. I realized that this was not going to give me enough space where I needed it most.... Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 02:48 AM	#3
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	....so I extended the line at the top so it reached 4 inches. This meant it doesn't have the same curve as stock but as the truck goes higher, the front axle is pushed farther back and this will give it the space where is it needed. The first photo is showing Dave using a nibbler to cut the lines I have drawn. The next one shows the lines I had originally cut on my inner fender well. My thoughts were to bend the tabs from the fender well up and put pieces in between them and weld it up. Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 03:01 AM	#4
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	I cut the amount I need to off of each tab to make it fit the new fender. This took a bit of time because I to put the fender on and take it off each time to ensure a tight fit. Then I decided I wanted to cut out a section of steel to make a new inner well all together. So I got out my 6X4 foot section of 1/16 mild steel sheet....doesn't everyone have one of those lying around? Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 03:13 AM	#5
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	But before I made the inner wells, I needed to reinforce the edge of the fender so I cut out a 3 inch strip to fit it. I used the excess piece I cut off the fender to get the pattern from, put duct tape along the edge and drew the line. I then placed the pattern on the steel sheet and plasma cut the piece. Then TIG tacked it on. Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 03:27 AM	#6
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	Now be careful when cutting your inner fender well tabs because I sliced the washer fluid bladder and dumped fluid everywhere. Finished TIG welding the rest of the fender edge and then made the inner fender well. I don't have any photos of the piece I cut out but all you need to do is use the same line from the fender cut out and then spread it out about 6 inches in width. Cut it out and tack weld is to the edge you've cut out on the fender well. We MIG welded the rest, but it could be TIG welded with some more effort. I also took the opportunity to TIG up holes around the cruiser I would be rhinolining. Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 03:38 AM	#7
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	These are the lines I choose for my rhinolining. I kept it pretty high on the sides because I wheel with a lot of brush and they scratch up paint pretty well. Thats all for now, but I am installing ARB lockers f&r this week and we just got a slee lift kit in for this rig at our shop. This summer's gonna be fun! Boone Attached Images __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 03:47 AM	#8
fjfar80 IH8MUD Regular Join Date: Jun 2006 Location: Hong Kong SAR Posts: 302	That is a lot of work...but, it looks great and I am sure that it will function really well. Great job and innovative. __________________ 1997 FZJ80 - Flareless, Lined, MetalTech Sliders, LandTank MAF, PM'd to the Gills, 285 BFG ATs, Alpine, and XM but, just starting (it's sitting in CONUS...a bit lonely..awaiting customization) 1997 BMW 528i - AC Schnitzer'd out (right-hand drive) 1988 E28 M5 - Currently being restored in the US "It is not the critic that counts" TR - 1910 http://faragesgarage.blogspot.com http://www.flickr.com/photos/mrgarage

06-17-08, 03:52 AM	#9
thestallionq8 IH8MUD Regular Join Date: Jun 2007 Location: Kuwait Posts: 391	Looking good! Would like to see the final result! __________________ 9K7ALI 1997 Toyota Land Cruiser GXR

06-17-08, 07:16 AM	#10
jfz80 IH8MUD Lifer Join Date: Jun 2005 Location: la punta alto TLCA# 16634 Posts: 1,569	cool project!!! looking foward to seeing it buttoned up after the lift. Have you checked out bjowett's write up on the rear trimming? LOOKS GOOD. __________________ 95 FZJ-80 Lifted, Locked, armored,37'd, blown and bigelow enhanced ; single digit MPG wondermobile 72 FJ-55 IPOR bumpers/sliders, SOA, 3'' BL, 8274, and a big ole F'n engine, 35' (for sale) 92 P/U stock, lil lady owned, gas miser/DD/worker aka tiny tim

06-17-08, 09:06 AM	#11
1shot1kill IH8MUD Junior Join Date: Sep 2005 Location: Oregon Posts: 143	Nice! __________________ IN VINO VERITAS 93 locked,sleed,Afrika Corps,sand ladders,snorkel,PIAA front/back,Arbed, 9k winch w/syn. od rope, Kaymared, quick release sways, OME, snorkel, dog ramp, Man-A-Fre rack, custom roof net, Lowarnce GPS, 4:88s, custom drivelines by NW Landcruiser, spacers, 38s - WIP!

06-17-08, 11:00 AM	#12
Izeloz IH8MUD Junior Join Date: Jun 2007 Posts: 128	Do you have an overall shot from the side to show how much you took out and how it looks?

06-17-08, 11:28 AM	#13
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	I am headed to the shop later today....I will take some more pics. When you're working it is hard to remember to take pictures. __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-17-08, 02:18 PM	#16
Dusty IH8MUD Lifer Join Date: Oct 2004 Posts: 1,457	thanks. real helpfull. I am doing similar right now to front end except I am cutttting out the radiator support on the sides also. more pics please. so how big of a tire are you going for? __________________ 97lx450 4" slee/j's, sliders, bumpers, 3" exhaust, custom turbo, HG pm/Valve job/seals, sweet custom skid plate, Sleeoffroad parts, Buys oe parts from Cruiser Dan used to have 37" swampers.. 1 tons and 42's pending..... Budget Blown 98 100 series. rear locker. 2008 6.7L dodge 2500 quad cab

06-17-08, 06:43 PM	#17
Clarkie IH8MUD Rookie Join Date: Jun 2008 Location: Perth Australia Posts: 12	nice job, should be able to get some big rubber under there now! __________________ Vx Sahara 1990 - ready for play

06-18-08, 05:31 AM	#18
BooKilla IH8MUD Regular Join Date: Aug 2007 Location: Portland, OR TLCA# 18193 Posts: 474	I will post some more pics soon. I must have sleep...I just spent two hours (from 1am-3am) replacing my alternator which just died on me. I am running on empty... ....and still checking mud at 4:31am __________________ The Boone '85 4runner (sold) '91 FJ80 (3fe powa) '94 FZJ80 (lockered) '98 4runner (sold) "Buying parts I don't need, with money I don't have, to impress people I don't know." Co-Founder of the Lake Oswego Militia

06-22-08, 06:13 PM	#19
lenross1 IH8MUD Rookie Join Date: Dec 2007 Location: Jackson, MS Posts: 38	wow always wondered what it would take to cut the fenders, now i know. you are braver than i am ! __________________ was that a speed bump... oh just a smart car 97 FZJ80 locked up on 36s 87 zuki on toyotas, 6.5 tcase, locked, 36s

06-22-08, 07:07 PM	#20
96Cruiser13 IH8MUD Regular Join Date: Jul 2007 Location: Greenville NC Posts: 261	i want that lift in my garage! hha looks great on the white __________________ Ryan 96 FZJ80... Firestone Destination MT 285/75, Linexed.. Thats it, for now ONSC

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