4Runner Fender Hack

[TheBandit]

This post includes pictures of trimming both the front and rear fenders on my 1st gen 4runner for added tire clearance, including making new wheeltubs for the rear. This is my first time doing this, so bear with me!

The offending sheet metal:



I used an adjustable square with a pencil strapped to it for making the fenders out. This is about 2" for the front fenders.



Am I really doing this?



Looks like I used a can opener.

[TheBandit]

Now that's better...



Looks funny with 33" tires



Firewall tub would be nice.



Time to start the other side.

[TheBandit]

Take this sheet metal!



I always end up with a goofy smile when I do this sorta thing



Almost... there....



Now I just need the courage to start on the rear.

[300sniper]

outa curiosity, what did you do to keep the cut from being razor sharp? on mine, i left about half inch of material beyond where i cut and folded it under for a non-meat eating finish.

[Izeloz]

Do people really have that much of an issue with the front fenders getting in the way? I only have some minor scraping on the firewall (needs tubbed) with 35's at full stuff. I left the fenders alone.

[TheBandit]

Originally Posted by 300sniper

what did you do to keep the cut from being razor sharp?

I'm gonna try out that door trim stuff that presses into place. Looks just like the factory chrome on the rear and should keep my skin happy. Folding the edge is a great idea.

Originally Posted by Izeloz

Do people really have that much of an issue with the front fenders getting in the way?

I have IFS and 33s. There's not a chance in hell my tires would even come close to the un-hacked fender near the top. But at the back it hit all the time. I decided to hack the whole fender rather than just the rear because I will be building an exocage and want to have room for future tire sizes.

[Izeloz]

Cool. Looks good.

[traxman25]

In my opinion they look much better hacked. I did the same but not as much and just to clear skin hating rusty edges. All I did to finish mine off was carefully sand with a flap wheel on my 4 1/2 inch angle grinder. Not sharp at all any more. Oh I cut mine with the angle grinder too, got then nice and smooth.

Good job with your hack, looks good.

[DRM]

How much can you cut in the rear before you have to weld the inner back to the outer skin?

[TheBandit]

Originally Posted by DRM

How much can you cut in the rear before you have to weld the inner back to the outer skin?

I don't think you can make any worthwhile cut without welding in some sort of inner tub patch. I think the max would be in the 1/2 to 1" range.

I cut a bit more than 2" from the front. I would like to cut a lot more from the rear so that the upper cut on the front fenders is level with the upper cut on the rear. I'm not sure if this will be possible because of where the rear seats are. I'll have to pull the interior panels off and take a close look at where things meet up.

[rockota]

I think 1" will be the max. EDIT: to keep the inner fender /edit www.toyotafiberglass.com is considering making front fenders w/ 1" larger opening all around - but with the factory toyota look - for those who need this mod but with a more stock look.

[]4RunnerKid[]

looking sweet Clint!!! wanna cut another set in a few weeks?

[TheBandit]

Originally Posted by ]4RunnerKid[

looking sweet Clint!!! wanna cut another set in a few weeks?

The sawzall awaits!

You gettin' some bigger tires?

My problem with your 2nd gen is if I pulled out the sawzall I would have to cut off the back roof

[Kajo4x4toy]

Looks good, I should be doing my front fenders tomorrow.

[4runner666]

Originally Posted by rockota

I think 1" will be the max. EDIT: to keep the inner fender /edit www.toyotafiberglass.com is considering making front fenders w/ 1" larger opening all around - but with the factory toyota look - for those who need this mod but with a more stock look.

these ones arn't quite as stock but still keep the square shape to them www.glassworksunlimited.com or here http://www.fourwheeler.com/brandpage...os/index3.html

[MattMan]

Originally Posted by TheBandit

I would like to cut a lot more from the rear so that the upper cut on the front fenders is level with the upper cut on the rear. I'm not sure if this will be possible because of where the rear seats are. I'll have to pull the interior panels off and take a close look at where things meet up.

You're gonna have to cut out the entire flare in the factory tin to match the height of that front cut. Might as well plan on some patch-work quilting with tin and a mig to keep the mud out of the ears of rear passengers.

[calrockx]

Originally Posted by TheBandit

The sawzall awaits!

You gettin' some bigger tires?

My problem with your 2nd gen is if I pulled out the sawzall I would have to cut off the back roof

and after his 2nd gen you can chop up my 3rd gen. ha!


nice work. it looks good and clean.

[GRMhick]

Originally Posted by DRM

How much can you cut in the rear before you have to weld the inner back to the outer skin?

I got about an inch and a half on both sides until the inner fenders were straight instead of bowed in.

[Lowtorious]

www.toyotafiberglass.com needs to make some trimmed 4Runner bedsides and somehow make the inner fender an easy mate, like a large internal lip or something.
I hope they come out with the trimmed front fenders because I need to replace both fronts and would like to go with glass but it wouldn't make much sense going with factory size..

[rockota]

Originally Posted by Lowtorious

www.toyotafiberglass.com needs to make some trimmed 4Runner bedsides and somehow make the inner fender an easy mate, like a large internal lip or something.
I hope they come out with the trimmed front fenders because I need to replace both fronts and would like to go with glass but it wouldn't make much sense going with factory size..

They are planning to do just that... And have asked for emails from intersted parties.

[VHD44]

Bandit: Sweet job on the fenders, what is the name of that ruler pencil tool you used to follow the orginal line of the opening, and where did you get it? Thanks.
Cory

[TheBandit]

Originally Posted by VHD44

Bandit: Sweet job on the fenders, what is the name of that ruler pencil tool you used to follow the orginal line of the opening, and where did you get it? Thanks.
Cory

Thanks! The tool isn't anything specialized. It's just an adjustable square like this one. I used a small block of PVC I had lying around and put it between a mechanical pencil and the square. Then I wrapped it with electrical tape to keep it together. It worked perfectly!

This thread is being hijacked by fiberglass fenders. The whole idea of this mod is it doesn't cost anything. The fiberglass fenders are nice, but they don't look that much different from a cut fender and they cost a bunch more. It is nice, however, when you plant them against a rock and they spring right back when you're done... assuming they don't crack. My brother has been running big prerunner glass fenders and hood on his truck for about two years and it sure was nice when he nose planted is truck. Everything sprung right back to where it was after he pulled the radiator support back out.

[]4RunnerKid[]

Originally Posted by TheBandit

The sawzall awaits!

You gettin' some bigger tires?

My problem with your 2nd gen is if I pulled out the sawzall I would have to cut off the back roof

let's do it...

ha ha, no... not yet at least. i'm just trying to get it all ready for SAS and 37s this winter... i'd like to cut the rear too, even though i know i won't be able to cut much... oh well. i'll hit you up when i get back in town. the sawzall looks so damn inviting...

[TheBandit]

Mike glad to hear you are SASing. I wish I had the money to do it myself. I think dual case will come first for me as that would be more useful I think than the solid axle. When I do my SAS I want to go three link, so it wont be until after I graduate. In the meantime I'm doing the inexpensive things that I think will be the most useful (ie, Chevy springs, sliders, Detroit)

Okay folks, day two is underway. I went for about 3.5" in the back, all the way around.



Here is where I cut the wheel tub. I used the sawzall from underneath.



What the cuts look like from the inside.



Peek-a-boo!

[TheBandit]

Hey Mike, can I borrow your 37s to check fitment?



When I get done with the wheeltub, this is gonna look badass. Can't wait to reep the benefits of increased uptravel without muching the fenders.



I have a lot more to do on this, but I have some schoolwork to finish. The truck is going to sit like this for about another week.

My tip for anyone doing this is to invest in a few sawzall blades. I did all of the above with ONE blade and a cutoff wheel. Using the same blade was a bad idea because on the second front fender and again on the rear the blade caught the sheatmetal and jerked it around pretty bad. That can happen even with a brand new blade, but after use the blade gets kinda wavey and makes it more likely.

Also I would say don't let the blade stop moving. If you hav to pull the blade out of the metal, do it quickly while it's still reciprocating. This will keep it from catching and fubaring the metal.