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View Full Version : Bolt on Tube Fender Build



Cruzin Illusion
May 30th, 2007, 06:25 PM
On the request of a moderator, he recommending to start a seperate thread on my tube fender build. I was not going to start my own because I did not want to clutter up the forum with mulitple of the same type of builds. But was told it was o.k. to proceed.

On April 27th I originally posted on another website my intentions to start a build project that I have been thinking about doing for a year:

Well I decided to pull the trigger on soon XJ tube fenders. I am gathering all the material I will need to complete my project. The rears will incorporate quarter guards with built in taillight boxes and the flares. The fronts will be built around a front fender guard that will include a fender flare to it. I was going to start the build this weekend, but some of the parts I needed to start were damaged in shipping and I am working on getting a replacement. I have wanted to do this project for a year but had other projects to finish first. I got a lot of inspiration from Brandons flares which pushed this project towards the top of my list. It was nice to see something simular to what I wanted to build and see it hold up to some actual use in Moab. I will keep you all posted.

By May 8th I had received all the materials I was waiting for and started my build:

Well here is an update on where the Jeep sits. I have installed and modified the rear quarter guards. I had to fabricate and add the front portion (dog leg) to both sides. I did this so it will be a true bolt on quarter guard with tube fenders. If you also notice the taillight boxes are part of the quarter guard also.

On the front fenders I have got the fender guards installed and started to trim the frenders to match.

Here are some pics:

http://www.thexota.org/d/4975-2/100_3651.jpg
http://www.thexota.org/d/4978-2/100_3652.jpg
http://www.thexota.org/d/4987-2/100_3658.jpg
http://www.thexota.org/d/4993-2/100_3660.jpg
http://www.thexota.org/d/5005-2/100_3664.jpg
http://www.thexota.org/d/5011-2/100_3666.jpg
http://www.thexota.org/d/5014-2/100_3667.jpg
http://www.thexota.org/d/4999-2/100_3662.jpg
http://www.thexota.org/d/5002-2/100_3663.jpg
http://www.thexota.org/d/5020-2/100_3669.jpg
http://www.thexota.org/d/5023-2/100_3670.jpg
http://www.thexota.org/d/5032-2/100_3673.jpg

The rear quarter guards are made by THOR4x4 and I am adding onto them with the permission of the owner, which I have talked to quit afew times. He built a set of tube fenders for the rear of his and sent me pictures of what he did so I could get some ideas. Sometimes it is just easier to start with someone elses part and work from there rather than reinventing the wheel.

The fronts came from Slickrock gear but I have had to modify them because they did not fit very well. If I could do it over again I would have made my own fronts. I had to go back and form the fronts to match the curve of the fender because of the fit. It will take a little work to get the finish right on these.

On May 13th I posted up some updated pictures of the build:

Here are some updated pictures:
http://www.thexota.org/d/5017-2/100_3668.jpg
http://www.thexota.org/d/5041-2/100_3676.jpg
http://www.thexota.org/d/5014-2/100_3667.jpg
http://www.thexota.org/d/5008-2/100_3665.jpg

I bent the tubes out of 1.5" x .120 D.O.M. It was tough to get the two bend on the rear portion of the rear fenders right along with the front two bends on the front fenders. Notice there is no kinkin of the tube in those area's.

http://www.thexota.org/d/5050-2/100_3678.jpg
http://www.thexota.org/d/5053-2/100_3679.jpg
http://www.thexota.org/d/5056-2/100_3680.jpg
http://www.thexota.org/d/5062-2/100_3682.jpg
http://www.thexota.org/d/5065-2/100_3683.jpg
http://www.thexota.org/d/5071-2/100_3685.jpg
http://www.thexota.org/d/5077-2/100_3687.jpg
http://www.thexota.org/d/5083-2/100_3689.jpg
http://www.thexota.org/d/5086-2/100_3690.jpg
http://www.thexota.org/d/5089-2/100_3691.jpg

Cruzin Illusion
May 30th, 2007, 06:28 PM
On may 18th I posted:

have the templates built for the metal skins and am in the process of making the skins. I do have the left side tacked up. Here are some updated pictures. Terry they should be ready to start paint prep soon. Let me know when you have time.

http://www.thexota.org/d/5116-2/100_3693.jpg
http://www.thexota.org/d/5119-2/100_3694.jpg
http://www.thexota.org/d/5122-2/100_3695.jpg
http://www.thexota.org/d/5128-2/100_3697.jpg
http://www.thexota.org/d/5134-2/100_3699.jpg
http://www.thexota.org/d/5137-2/100_3700.jpg
http://www.thexota.org/d/5143-2/100_3702.jpg
http://www.thexota.org/d/5146-2/100_3703.jpg
http://www.thexota.org/d/5149-2/100_3704.jpg
http://www.thexota.org/d/5152-2/100_3705.jpg
http://www.thexota.org/d/5155-2/100_3706.jpg
http://www.thexota.org/d/5158-2/100_3707.jpg
http://www.thexota.org/d/5161-2/100_3708.jpg
http://www.thexota.org/d/5164-2/100_3710.jpg
http://www.thexota.org/d/5167-2/100_3712.jpg

I tacked welded the inner seem from the bottom. I figure I will just keep rotating around the vehicle to allow for cooling so as to not build up to much heat and warp the sheet metal. I figure we could run a very very small amount of filler to give it a very small transition. They fit very tight against the 3/16" body panel. I also figured it would be easy to grind the welds down on the outer sides and it should give it a nice transition into the tube.

Here are a few outside in the sun.
http://www.thexota.org/d/5170-2/100_3713.jpg
http://www.thexota.org/d/5173-2/100_3714.jpg
http://www.thexota.org/d/5179-2/100_3716.jpg
http://www.thexota.org/d/5182-2/100_3717.jpg
http://www.thexota.org/d/5185-2/100_3718.jpg
http://www.thexota.org/d/5194-2/100_3721.jpg

Cruzin Illusion
May 30th, 2007, 06:30 PM
I am in the process of finish welding them up and grinding them so there are no seems. My goal is to have no welds showing. They will be very clean looking and not rough.

http://www.thexota.org/d/5254-2/100_3741.jpg
http://www.thexota.org/d/5242-2/100_3737.jpg
http://www.thexota.org/d/5236-2/100_3735.jpg
http://www.thexota.org/d/5230-2/100_3733.jpg
Not to bad for welding these up side down in the wheel well:
http://www.thexota.org/d/5227-2/100_3732.jpg
http://www.thexota.org/d/5218-2/100_3729.jpg
http://www.thexota.org/d/5221-2/100_3730.jpg

Then they will be preped for paint and the paint scheme will match what I had previous. Orange on the body and Silver on the flares and below the lower body line.

Cruzin Illusion
May 30th, 2007, 06:33 PM
At this time they are at a friends (87xjco) body shop being final preped for paint. I am hoping by sometime mid next week we can have them ready to shoot. I will keep everyone posted on the progress through this thread. If you have any questions feel free to ask.

Thanks,
Cruzin Illusion

Eric
May 30th, 2007, 06:47 PM
Very clean, nice work :thumbsup:

05Ruby
May 30th, 2007, 06:54 PM
X'cellent workmanship. Thanks for posting the pictures., I hope I can get close when I go after mine.:thumbsup: :beer:

ColoradoXJ
May 30th, 2007, 07:16 PM
very, very nice :D

REDLYNER
May 30th, 2007, 07:32 PM
Wow! The hard work and attention to detail is obvious. Can't wait to see it painted!

FLATIRON FAB
May 30th, 2007, 07:32 PM
Well done! They turned out great.

cheftyler
May 30th, 2007, 08:06 PM
Those look great, always been a a fan of your XJ

DADA_JEEP
May 30th, 2007, 08:17 PM
dood you got mad fab skilz

Cruzin Illusion
May 30th, 2007, 10:44 PM
Here a few of them being preped for paint:

http://www.thexota.org/d/5266-2/Dsc03350.jpg

Here is picture of smoothing out the seam with All Metal:

http://www.thexota.org/d/5284-2/Dsc03360.jpg

We used seam filler on the lower side to keep water from catching in the radius portion between the tube and the sheetmetal fender portion. I have heard a lot of TJ guys end up with rust in those areas and I Terry is trying to prevent that.

http://www.thexota.org/d/5308-2/Dsc03361.jpg

Steven_Mc
May 31st, 2007, 08:03 AM
Wow! Looks Great, definitely very innovative setup!

TrailTJ
May 31st, 2007, 08:33 PM
Awesome fab work as always Tom! I can't wait to see what they look like with paint on 'em.

CyllaibusCstms
May 31st, 2007, 08:42 PM
Those look good Tom! When you getting them painted. I do want to point out to all you guys that I was the first one for these thing and gave everyone the bug. But I know you give me credit. They look good though.

Cruzin Illusion
May 31st, 2007, 10:42 PM
Those look good Tom! When you getting them painted. I do want to point out to all you guys that I was the first one for these thing and gave everyone the bug. But I know you give me credit. They look good though.


This is very true Brandon. If it wasn't for seeing yours in action in Moab I probably would not have started these until next winter, but with the way they performed you got me in gear to get my design going. Thanks for the help and the suggestions on how to improve them over your design. I do like how yours is clean and smooth and does not show welds.

87xjco
May 31st, 2007, 10:52 PM
Those look good Tom! When you getting them painted. I do want to point out to all you guys that I was the first one for these thing and gave everyone the bug. But I know you give me credit. They look good though.

There must be a good story to how you came up with yours Brandon, and i'd like to hear about the build process too!

Any pic's of your build?

Frank Z
May 31st, 2007, 11:13 PM
I think this Canadian built his first...

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850005.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850018.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850010.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850009.jpg

Cruzin Illusion
May 31st, 2007, 11:21 PM
I think this Canadian built his first...

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850005.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850018.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850010.jpg

http://s67.photobucket.com/albums/h311/heeps4ever/?action=view&current=01850009.jpg

Who cares who built them first. Let's just get this thread back on track.

Frank Z
May 31st, 2007, 11:22 PM
Who cares who built them first. Let's just get this thread back on track.EXACTLY!!! Thanks Tom!:beer:


Nice work BTW!

Oscar
June 1st, 2007, 09:12 AM
Man those are some mad skills looks great

XJ Flex
June 1st, 2007, 09:20 AM
If you dont have the time to do tube yourself www.slickrockgear.com has a set of flares and corners for $700.00 bolt on and go. Cruzin you did a great job on yours not trying to steal a thread but showing what else is out there. Hammer

CyllaibusCstms
June 4th, 2007, 05:12 PM
I enede up building mine because my XJ is a 2000 and I got sick of picking up fender flares every time i went four wheeling. So I started looking for someone who built rear crusher corners for a XJ. After I found performance metal works in the Springs I got a set of his corners and door guards. I then modified a set of rear tube flares from poison syder to fit the corners. At that point I decided i should build a set for the front as well so i got another pair of rear fenders from PS for the rear of a tj and had to section 10" out of one side of them and build a sub structure that went back to the unibody and coil tower. I cant find my pictures of them, but Tom do you still have the ones you put up before if you wouldn't mind. (P.S. this isn't Canada!)

sonofmayhem
June 6th, 2007, 08:29 PM
Are they done yet?:D

Cruzin Illusion
June 16th, 2007, 12:25 PM
It has been a while but I thought I would share a few updated pictures. Here are some pictures of them in primer and with the silver paint on them. The orange and clear are being painted today. I am hoping that I will install them Monday or Tuesday. I want to thank Terry 87xjco and Jamie for the help on getting these preped and painted.

http://www.thexota.org/d/5559-2/Dsc03392.jpg
http://www.thexota.org/d/5562-2/Dsc03393.jpg
http://www.thexota.org/d/5573-2/100_3793.jpg
http://www.thexota.org/d/5576-2/100_3794.jpg
http://www.thexota.org/d/5579-2/100_3795.jpg
http://www.thexota.org/d/5582-2/100_3796.jpg
http://www.thexota.org/d/5585-2/100_3797.jpg
http://www.thexota.org/d/5588-2/100_3798.jpg
http://www.thexota.org/d/5591-2/100_3799.jpg

Cruzin Illusion
June 18th, 2007, 09:54 AM
The paint is done and they came out awesome:

Thanks to Terry 87xjco and Jamie for the help on getting them finished up. Terry is a bodyshop manager and does awesome work.

http://www.thexota.org/d/5757-2/DSC03394.JPG
http://www.thexota.org/d/5759-2/DSC03395.JPG
http://www.thexota.org/d/5761-2/DSC03396.JPG
http://www.thexota.org/d/5763-2/DSC03397.JPG

ColoradoXJ
June 18th, 2007, 10:01 AM
those are sick :D can't wait to see them on the xj

Scooter
June 18th, 2007, 10:17 AM
Sweet...........:thumbsup:

Nice work as usual!

TrailTJ
June 19th, 2007, 10:54 PM
Those look awesome Tom! Now get 'em on the Jeep...:D

Cruzin Illusion
June 19th, 2007, 11:25 PM
Those look awesome Tom! Now get 'em on the Jeep...:D


They are installed a look awesome. It was dark when I finished so I will take some pictures tomorrow and post them up. I am happy they are done. The Cherokee projects are done for the rest of the wheeling season.

Cruzin Illusion
June 20th, 2007, 04:22 PM
Here is the finished product:

http://www.thexota.org/d/5839-2/100_3801.jpg
http://www.thexota.org/d/5841-2/100_3802.jpg
http://www.thexota.org/d/5843-2/100_3803.jpg
http://www.thexota.org/d/5845-2/100_3804.jpg
http://www.thexota.org/d/5847-2/100_3805.jpg
http://www.thexota.org/d/5817-2/100_3806.jpg
http://www.thexota.org/d/5819-2/100_3807.jpg
http://www.thexota.org/d/5821-2/100_3808.jpg
http://www.thexota.org/d/5823-2/100_3809.jpg
http://www.thexota.org/d/5825-2/100_3810.jpg
http://www.thexota.org/d/5827-2/100_3811.jpg
http://www.thexota.org/d/5829-2/100_3812.jpg
http://www.thexota.org/d/5831-2/100_3813.jpg
http://www.thexota.org/d/5833-2/100_3814.jpg
http://www.thexota.org/d/5837-2/100_3815.jpg

REDLYNER
June 20th, 2007, 04:25 PM
Wow!!!:eek:

Looks great!!!

ColoradoXJ
June 20th, 2007, 04:30 PM
that looks awesome :D



btw, tell your neighbor to mow his grass.

RockYacht
June 26th, 2007, 11:04 PM
Nice work Tom!

Bob

hightimes2
June 26th, 2007, 11:11 PM
Very nice work. How much to build another set and a int. cage lol

Cruzin Illusion
June 27th, 2007, 07:28 AM
Very nice work. How much to build another set and a int. cage lol

I thought about build a few sets of the fenders but came to the conclusion that I could not make them cost effective enough and build them to a quality that I think would be exceptable. In my experience it seems that every XJ is a little different and would want to build every set on the particular Cherokee to get them to fit right. I guess what I am saying is if I built a set for someone I want them to look right and fit right. I would not put them on someone elses Jeep if I would not put them on mine.

hightimes2
June 27th, 2007, 11:20 PM
I thought about build a few sets of the fenders but came to the conclusion that I could not make them cost effective enough and build them to a quality that I think would be exceptable. In my experience it seems that every XJ is a little different and would want to build every set on the particular Cherokee to get them to fit right. I guess what I am saying is if I built a set for someone I want them to look right and fit right. I would not put them on someone elses Jeep if I would not put them on mine.


Its ok I'm not picky lol but honestley very nice work on the fenders.