November 14, 2018

Note: I did this on two different days, for a few weeks i actually had only the front flares installed, you may notice a gap in the write-up for the front, and rear flares. I did the front first, and the rear later.

–Front flares

As anyone who has ever owned a YJ or CJ and tried to install larger tires knows, there isnt a lot of room under the fenders. Some trail rigs have simply had the flares removed all together. That isnt an option for me as this in my Daily Driver and state inspection laws prohibit me from removing my Fender Flares. So, the next option is to find a way to add more clearance and still keep the flares. Thats where the TJ flares come in.

So, my friend Adam (Rave) and I (YJ Nate) set out to accomplish this.


Here is my YJ Islander before we started wrenching and cutting. Pretty, isn’t it?

We decided to go out and take a few flex shots before we got to work.


Here is my rear passenger side tire fully stuffed into my fender.


This is my rear tire contacting my rear fender. One thing that I aim to fix!

Didnt get as many pictures of the actual removal as i wanted, but its really simple.

In the front its as simple as: Remove the marker lenses and remove the lights from the lenses. Then remove all of the screw/fastener assemblies that hold the flare on. Then remove the flare itself. Pretty basic. Youll end up with this.

The rear is only slightly more trickey. You have some tight working spaces and a plastic shield on the inside of the fenderwell to worry about. Still pretty self explanitory. You should end up with something close to this:

Ok, next we washed off the dirt that had built up under there over the years and made sure it was all nice and clean. Then we decided that it was time for Lunch. The Jeep was blocking just about every other vehicle in the driveway, so we put the front turn signals back on and took it down to the pizza shop. Got a few strange looks, and a nice State Cop told us “Hey, you have to put Fender Flares on that!”, but he didnt give us a ticket (whew!). Here are some pictures I took after we got back:

Well, I was just starting to like it like this, but I guess I have to put the flares on. Gotta be legal and all.. My tires stick out about 8″. Well over the allowed distance, which i think techincally is that they cant stick out AT ALL!

After making sure that the surface was nice and clean, I started by taping up the area that I would be cutting on. This helps protect the paint, and also gives you a surface to trace the outline of the flare on.

Here it is all taped up.

Basically what we did was take the new flare, line it up with the top of the fender using something relatively straight to do so (thats why there is a 3/4″ wrench on the fender in the below picture). Then use a marker to trace the inside of the flare on the tape. Worked pretty well. Essentially the YJ’s fenders are the same shape as the TJ flare. Only 2 spots are different. Right above the tire, and right behind the front face of the fender. The only cut that is really nessessairy (as far as i can tell) is the one above the tire. This will allow for about another inch of tire clearance.

Here is my beautiful line!

Now, fire up that Saw! Time to do some trimmin!

On this fender I did my best to cut everything that the line said to. On the other fender (not pictured because I screwed it up) I didnt cut the section right behind the front face of the fender as it didnt seem nessessairy. (Note: the 3/4″ wrench is still on the fender so the vibration of the Saw will cause it to fall on me and the most in-opportune time)

Ok, so we moved the wrench before it fell on me. I think Adam noticed it before it fell (thanks Adam!). So here i am pulling the pieces out of the fender after cutting them up. This went pretty well actually. I was all worried about nothing I guess. We mounted the flare back up again to mark the holes for drilling and then I drilled the holes. Now its time to remove the tape.


Here it is, with the tape removed and the fender trimmed. I think I did a pretty decent Job. This is the first time I’ve ever touched one of these saws, and I didnt even lose a finger!

ok, now all thats left is to mount the new flares right? Well, youre close. There is a little prep work that needs to be done on the new flares.

First there are some Alignment studs that you can either remove, or drill holes in the fender for. I opted to remove them. So I cut them off with a Utility knife. There is also a lip on the inside of the flare which isnt really needed. So, I removed it completely. Now that I look back at it, I think i would rather have had the patients to get all of the cuts I made just right, and mount the flare with the lip intact. But.. its too late now. Here I am prepping the flares.

Now, the moment of thuth, mounting the flares to the body. This is pretty simple, just line up the holes, and put the mounting hardware back in. A member of Jeepaholics Anonymous was kind enough to send me brand new hardware. Guess I owe him now. Anyway, I used that hardware, but the stock hardware “Should” work. I dont see why it wouldn’t.

Here are some pictures of the newly mounted flares!


Side view of the new flare


Adam installing the pass. side flare


A close-up of the driver’s side flare.


You can see that the flare extends past the fender. I will someday trim that and get it level with the bottom of the fender.

Now, all thats left is the marker lights, i didnt get any pictures of the install of those. I had to buy some new marker lights as the flares didnt come with any. Got them at a dealer for $12 a piece. To install them, they sort of clip in, but you need to put something on the post on the back to keep them in place. So we took a small nut and forced it on the plastic stud, making threads as we went. It worked well on the drivers side, but the pass. side gave us a little problem. We got it on there though.

The next thing to tackle is getting the lights into the new marker lenses. The factory YJ lights fit with a little modification. There are 4 tabs on the YJ lights, and 2 tabs on the TJ lights. So, cut off 2 of the tabs. 2 of them have the little “Ramps” on them, the others dont. I cut the ones that did not have the little ramps.

So there you have it, the fronts are done. I didnt get the rears done yet as i couldnt make them work along with my stock YJ side steps. So they will wait until another day.

— Rear flares

Well, we got the front flares done in the first secion of this write-up, so now its time for the rear.


Here is a picture that we took before even beginning the project. Here you see my rear passenger tire contacting the body at full flex. Keep this in mind, ill have a comparison later! 🙂

So, the first thing to do was to remove the rear flares, and figure out something to do with those stock sidesteps. Theyre too long to allow for the TJ flares.


Here we are about where we left off last time. Rear YJ flares removed, front TJ flares installed.

So, for those sidesteps. They’ve got a plastic-like (yurethane?) flare extension that connects to the front flare, and runs the whole length of the vehical, well, back to the rear flare anyway, at that point it just about contacts the stock rear flare and is rounded off. This has a plastic step right under the door, which is supported by a metal bracket that is attatched to the bottom of the tub, and extends out to the edge of the flare extension. The plastic step is bolted to the side of the tub, and through the flare extension, into this metal bracket. Clear yet?

Heres what I did. Remove all of it, except the metal bracket, this leaves some holes in the side of the tub, but you can reinstall the bolts to cover the holes. Then mount the plastic step right to the metal bracket. It ends up something like this:

After getting all of that taken care of, I washed the area that will be taped, and cut.


Then I taped up the area that the flare will be mounted to, clamped the flare in place, ans traced my line. This picture is to give you an idea of the dfference between the TJ and YJ wheel openings.

I was working alone today, so i could not get any sites/default/files/flares/images.rear of me cutting, but its very similar to the front, but a little easier, not as many tight corners or complicated things. The only somewhat tricky part is yet to come.

There is a wall at the back of the wheel opening, which seporates the wheel opening from the area where the gas filler and tail light electronics are. This wall is a slight poblem. I wasnt about to remove it, and didnt want to cut through it, but it was in the way of where i was cutting. So heres what I did.


I cut a little notch out while cutting the scrap out. Made sure it was just about as big as the “Wall” in the back


Then I pounded that notch inward, tward the wall, with a hammer.

Once it was pounded out of the way, I cut a notch in the “Lip” on the flare to allow that “Wall” to poke through a little.

It all seems to work out pretty good if you ask me. Maybe you’ve got a better way to do it, but this is just fine for me! 😛

So, Here we have the finished product!

Passenger’s Side

Driver’s side

Slightly cleaner Drivers Side

One stuffed Tire (think back to the previous image, a lot more room now!!)

One nicely drooped tire! Plenty of room now!

Tech

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