Direction for cutting the front core support

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H

Hunter Christian

10 Year
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Sep 5, 2015
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So I want to trim these up and want some advice on the best way to execute this before i start hacking away.

What tools seemed to work best?
How far up and over is enough?
What welding was needed after?
Etc etc etc...

Also can I relocate the a.c. dryer with what's there or do I need a relocation kit?

Sorry if this has been discussed already.

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We need @Apounder @ExpoMax there's many more but can't remember their avatar.
 
I trimmed mine up to come in line with the 4x4 labs bumper.

What you need to take into account is that the weight of all of the items on the fender rest on this area and is transferred to the front clip and moreover the front body mount. If you take too much off and have too much weight on top you will start seeing your batteries sink.

I'll try and snap some photos of what I did to fix this.
 
I don't have many great pics (can get some better ones tomorrow).

What tools seemed to work best - I used a sazall and a 4.5in cut off wheel on a grinder.

How far up and over is enough - That's up to you, If you want the valance gone like I did, then all the way up to the bottom of the headlight. Whatever Ac line is in this pick I left alone. Just cut up to that, then kind of curved around it. Just go for it, its not hard, just time consuming. This will come into play on the other side more, but there are wires and several other stuff you have to watch out for. For the Driver side I ended up taking the battery tray out to move wires outa the way.

What welding was needed after? - I wanted to seal the core support ends, so I just cut some plate to fill in the 2x2ish hole and welded that. Totally not needed though. Also welded the inner fender to the core support because I plan to seal the inner wheel-well up so I don't get water blowing into my engine. Really don't need any welding if you don't want too.

The AC dryer can be bent all the way up to the underside of the headlight. It is really hard not to kink the lines bending it up that far, so be careful. I will get some more pics of the AC dryer side for you tomorrow
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excessive said:
I've never herad of an A/C dryer relocation kit, i wish there was one. Custom lines are your only option.
Click to expand...

Ebay sells these great lines that convert hardlines into soft ones. Who knows if they actually work, but if my lines ever blow up from being bent so far I plan to buy them and move my AC dryer into the battery tray.

FIX REPAIR A/C LEAK - LINE TO HOSE SPLICE KIT WITH 2 FT HOSE FOR 5/16" LINE | eBay

A/C Line Repair Kit 3/8" Repair A/C Lines AC Tube Repair AC Line Splice Kit | eBay
 
ExpoMax said:
I don't have many great pics (can get some better ones tomorrow).

What tools seemed to work best - I used a sazall and a 4.5in cut off wheel on a grinder.

How far up and over is enough - That's up to you, If you want the valance gone like I did, then all the way up to the bottom of the headlight. Whatever Ac line is in this pick I left alone. Just cut up to that, then kind of curved around it. Just go for it, its not hard, just time consuming. This will come into play on the other side more, but there are wires and several other stuff you have to watch out for. For the Driver side I ended up taking the battery tray out to move wires outa the way.

What welding was needed after? - I wanted to seal the core support ends, so I just cut some plate to fill in the 2x2ish hole and welded that. Totally not needed though. Also welded the inner fender to the core support because I plan to seal the inner wheel-well up so I don't get water blowing into my engine. Really don't need any welding if you don't want too.

The AC dryer can be bent all the way up to the underside of the headlight. It is really hard not to kink the lines bending it up that far, so be careful. I will get some more pics of the AC dryer side for you tomorrow
View attachment 1544704
Click to expand...

Sweet thanks! Yeah if like to see what you did on the driver side when you get around to getting a pic. I have what tools I need and mig welder so I guess I'll just see what I like when I get there. Thanks for all the feedback everyone!
 
I cut it up to where it is in the first picture and then cut slits and folded the "valence" portion up and back over the inner fender.

I also put the winch on top of the frame rails and tucked it back as far as possible without MAJOR surgery.

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I don't have AC so I can't comment on that. I intend to build a bumper that wraps under the headlights so I left a bit of the inner fender/valence/core support hanging about an inch below the headlights.
 
Hunter Christian said:
That looks awesome! See I'm debating on leaving the blinker lights or just going to the bottom of the headlights like you did. What do you have for front turn signals?
Click to expand...

You can swap the turn signal bulbs and harness into the marker light housings. Everything plugs right in.

Then you can do whatever you want for marker light.
 
Hunter Christian said:
That looks awesome! See I'm debating on leaving the blinker lights or just going to the bottom of the headlights like you did. What do you have for front turn signals?
Click to expand...

Just take the socket out of the stock turn signals, drill a hole into the bottom of the side indicator lights, plop it in, and now you have turn signals and indicator lights!
 
ExpoMax said:
Just take the socket out of the stock turn signals, drill a hole into the bottom of the side indicator lights, plop it in, and now you have turn signals and indicator lights!
Click to expand...

I liked that so much I just did it. Worked great.
 
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