whats the cleanest way to cut fenders?

[crawlin91]

Ive got a sawzall and 4" wheel grinder. Then was thinking bend edges in with pliers and add a little bed liner to protect against rust. But what have you guys done? Pics? I want it to look as clean as possible.

 

[sbsrlewis]

Look at my article under "Bodywork" in the Tech Section. I used a Plasma Cutter to cut mine. If I didn't have it I would have used a cutoff wheel for a cleaner cut. If you use a jigsaw make sure you use a fine blade and change often.

 

[koda6966]

Look at my article under "Bodywork" in the Tech Section. I used a Plasma Cutter to cut mine. If I didn't have it I would have used a cutoff wheel for a cleaner cut. If you use a jigsaw make sure you use a fine blade and change often.

And that you can hold it VERY steady for a strait cut.

 

[crawlin91]

those look good. Adding plasma cutter to Christmas wish list. Well I will probably be using the wheel method and just take my time, cut a little less than I need and grind it smooth. I will get pics up when shes done.

 

[rickcdewitt]

haha yeah try and catch your truck on fire with a plasma,and then get a tetnus shot for cutting yourself on the unfolded edge.

seriously though if paint is your main concern use a couple layers of tape over the part that will remain and jigsaw it,then smooth it out with the grinder sparingly to not build up heat.the sawzall is not a precision tool ,lol!(edit:i did mine with a sawzall but its recip action throws the blade a little too far and will make it catch and slam the painted surface if you aren't careful.a 20$ air body saw would work good too.)

i would fold the edge so it won't flap in the wind,and you can pick up the truck from the opening still if you want to rock it or help with a stuck.besides all factory openings are folded for support. it will crack the paint on the fold though so have some touch up handy.the slower you go and the less you bend at one time the smoother it will come out.

theres a reinforcement panel in the rear opening you'll want to weld or screw back to the wheelwell so it won't flop.

the trucks dented up but the folds are clean

 

[4x4junkie]

Done with a Sawzall:

I used the finest tooth blade available (32TPI IIRC), laid down a piece of masking tape to follow as a guide, and went real slow with it. Afterward I used a Dremel to smooth down the edge.

 

[crawlin91]

Im liking it 4x4Junkie, I was thinking it might be a pain in the ass to run a nice curved line around the fender well with the cutting wheel, and I do have a dremel so I may try your approach, just gotta get me some new blades. I went through all of mine on the gas tank skid plate and crossmember when I did my driveshaft swap.(just cut the whole thing right out instead of messing with all those damn rivets) Which by the way is flawless and without vibration.thanks ranger station.

 

[Tony Raine]

jigsaw, hammer, and pliers

 

[Hardwareman]

Used to be a member around called crbnunit.

I recall he used an air nibbler and swore that made it very easy. Just don't track the little metal wafers left behind into the house or there'll be hell to pay with the little woman.....haha




Allen

 

[koda6966]

He's still around I think. Just doesn't log in much.

 

[kris97ranger]

i just used a 4" grinder with a cut off wheel. and instead of cutting in and going through the whole thickness at onece i just dine lines over and over till it was ground down enough to come off. really clean and easy to do curves. i also redid the 90 degree bend as well so it looks stock just alot bigger
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[MountainMike]

One of these guys with a thin disc.

http://www.afrema.com/ProductsImages/Products/2007530163117_HIGH SPEED AIR CUTTER.jpg

 

[kris97ranger]

http://img-2.h-img.com/media/img/s/m/i/l/milwaukee-4-1-2-in-magnum-sander-grinder-406521.jpg
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