sexybluelady:
There are 3 ways I have extended my fenders;
1) I used Cove base material with thin Aluminum on the tire side for extra strength. Just bolted them on, worked for years, no beauty queen but lots of original.
2) I bought a set of flares from the yard off of a early 90's-late80's Jeep Cherokee (sorry, I don't remember the year). Didn't line up perfect and didn't extend out quite as far but still looked better than the cove Base set.
3) I finally gave in to the desire to feel cooler and dropped the piggy bank for the Bushwacker Cutouts. They don't work any better, their not as forgiving as the cove Base but do look better than either other attempt. In regards to longevity, they have been installed since 1998.
I have learn to used hex head sheet metal screws instead of the supplied blind rivit fasteners. With the rivits, sometimes they would pull a little tight, even with the gimp gasket and cause a crack. Using the hex heads, I apply some red lock tight and just let it be snug, not overly tight. Any cracks, just buff it up with fender washers, fixed ..)
Also, The BroncoGraveyard.com and James Duff LLC sell there own, new fender flare kits for your truck.