Cutting Fenders - What to do with edge.

[Walking Eagle]

Cut front fenders - pics at post 30

You can follow the discussion as to how I got to where I did and why I did what I did - or you can skip to post 30 and see what I did.



Please don't say search - I've tried, and I can't find anything on what folks are doing with the edge once they've cut the fenders. I cut 2" out yesterday, just enough to get rid of the major dents and I cut the inner fender to spread it up, now I need a 90 at the bottom of the fender to make it hold the inner fender. I looked at the metal tech thread, and I can't tell what they did to create that 90. Found a couple where people just completely removed the inner fender, and not really up for that. I had thought I could just bend it back over, but the fender metal is thicker than I thought it'd be. Well, at least most of the dents are cut out.....

 

[gotmud]

Hard to give you advise without seeing exactly what you are up against, what tools you have access to or what your skill level is, but...
I have used a piece of sheet metal, a brake and an english wheel to first make a 90 in the sheet metal and then form it to the contour of the wheel opening. I then spotted it to the inner fender and then to the fender/quarter panel.

You could probably get similar results with a piece of thin guage angle iron and a cheap english wheel from HF.

 

[Uncle Grumpy]

What about bending 3/8" or so inwards and fabricating a jig like this to give it a symmetrical bend at 90? That would provide a lip and a somewhat finished look.

 

[jlg32281]

Use a fender roller. You rent one from a body shop or something.
RollYourFender.Com - Instructions - Fast, Easy, & Affordable Professional Fender Lip Roller Rental

 

[dafun1]

They cut slices into the inner fender and bent them upward, then welded pieces into fill the gaps and welded a thin piece 90 degrees on the outer edge and put rubber between the two pieces and it is held together by tension. PKP80 (Sam) cut the inner fender completely out and I did the same thing. This exposes the stock air intake and a snorkel is highly recommended. I'm sure one of the Oregon/Metaltech guys will chime in with more details.

 

[trd55]

Smart thing would have been to cut slices in the outer and bent them in, creating the ledge to tie the inner to. Then just fill in with flat sheetmetal. This is what I did when I cut the rears. Looks factory almost. You could cut another 3/8"-1/2" and do the same, if you have enough material.

 

[dafun1]

Again, why not just remove the inner fender (much less work) like this:

 

[Walking Eagle]

You could probably get similar results with a piece of thin guage angle iron and a cheap english wheel from HF.

Was thinking about this option.

Smart thing would have been to cut slices in the outer and bent them in, creating the ledge to tie the inner to. Then just fill in with flat sheetmetal. This is what I did when I cut the rears. Looks factory almost. You could cut another 3/8"-1/2" and do the same, if you have enough material.

I guess I did the smart thing then. Was figuring on 2" or so, so I cut at 1.5" to start - saw the Metal Tech folks went 3", but figured I could cut more once I figured out what I'm doing. Actually the 1.5 - 2.0" seems to put the inner fender about horizontal.

Again, why not just remove the inner fender (much less work) like this:

Again?

I think it looks more finished with the inner fender, this is after all still a Lexus Not quite sure how it's less work if I have to put a snorkle on? And I still have to do something about the raw edge of the fender. Thanks for the option though.


Been debating back and forth between the option of cutting slits and bending or the angle sheet approach. Would seem faster / easier to add an angle piece, spot weld around the edge and then seal it before re- durabaking it. Luckily I've found Durabak hides many sins.

 

[dafun1]

To each his own. Yeah red 16.5" wheels, 37" Goodyear Hummer take-offs, and a giant front stinger with a skull...that screams true "Lexus" man . Roll or weld away. Homemade snorkel cost me about $50...

 

[super90]

Here is the process and tool, fully detailed by the Porsche guys:

Fender Rolling Party - Pelican Parts Technical BBS

 

[darwink1]

I would use a length of solid round stock. Bend it to shape and tack. Should provide a ledge and stiffen things up a bit.

D

 

[Walking Eagle]

To each his own. Yeah red 16.5" wheels, 37" Goodyear Hummer take-offs, and a giant front stinger with a skull...that screams true "Lexus" man . Roll or weld away. Homemade snorkel cost me about $50...

Dude - dial the attitude back a bit - As I said, thanks for the option - but as I said from the begining not interested in that option.

Here is the process and tool, fully detailed by the Porsche guys:

Fender Rolling Party - Pelican Parts Technical BBS

Since this has come up several times - this is not what I"m talking about. That is for taking the 90 that is normally on the inside edge of wheel well openings, like what is on the back wheel wells and folding it back closer to a 180. This would be fine for the rear of the 80 if you were just trying to gain a 1/8-1/4". What I'm talking about is cutting the fender back 1.5". Then reforming the ledge to hold the inner fender - which is also reformed.

If I cut a buch of slits so I can bend it over 90, I'm stuck with a bunch of slits to weld up w/ a flat piece behind it. If I do an angle, I have to weld a billion little spots along the edge (probably could get away with a hundred since I'm re-durabaking.). Just wish I had some photos to go off of. I have a plan in mind now, and will shoot some photos as I go, unless someone throws up something new to change my mind.

 

[Tenzig Norgay]

This may be a whole lot more work, but I'm completly satisfied with the end result. Once all the metal was were I wanted it, I fiberglassed the outside, and on the inside as well, multiple layers, lapping up onto the metal over a foot. Duraglassed and filled in low areas, painted and FABEC. Its a built in slider.

 

[dafun1]

Walking Eagle: just being sarcastic man. I actually admire your rig and respect your desire to keep a finished look. Have fun with your fender project

 

[Wrench]

It's not a Lexus anymore.

 

[Walking Eagle]

It's not a Lexus anymore.

It's a White Trash Lexus.... Still says Lexus on the title, the tailgate, and even has a nice GOLD Lexus emblem on the grill. The hatch key cover though some would be thieves took care of destroying.

 

[headhunter]

pacer fender flare would be a easy solution around 70 bucks .

 

[Walking Eagle]

pacer fender flare would be a easy solution around 70 bucks .

It's not really a solution. It doesn't give me anything to mount the inner fender to, nor does it cover the sharp edge if I got the surface mount ones, and I'd still have to do something to get the 90 to use the other mounting style.

They will however work to cover any sins I may commit in finishing the edge, and will gain some tire coverage for legal requirements. They may even inhance the white trashyness of the truck.

 

[Walking Eagle]

This may be a whole lot more work, but I'm completly satisfied with the end result. Once all the metal was were I wanted it, I fiberglassed the outside, and on the inside as well, multiple layers, lapping up onto the metal over a foot. Duraglassed and filled in low areas, painted and FABEC. Its a built in slider.

Definately looks like a whole lot more work, but, still, currious if you have any in-progress photos.

 

[CreeperSleeper]

Personally, I didn't attach the outter fender to the inner fender. I cut 3" out of the outter fender, then built inner fenders out of sheet metal. It's a tight enough fit that it doesn't rattle when the outter fender is bolted back on and it is still easy to remove if needed.

It's in this thread: https://forum.ih8mud.com/80-series-tech/204884-some-redneck-bodywork-finished.html