Fender Hacking Method...

[64suburban]

Cut off wheel gets my vote.

They wont be safe unless you fold the edge over. Ask me how I know (dont swing a sledge hamer at your leaf springs unless you fold the edges over All the way to the bone baby!

First of all ouch!, then second cut off wheel gets my vote, the fender dosen't have to be stable, where it would have to be pretty secure for you to use a sawzall. Other wise the sawzall blade just jerks the fender back and fourth and it ruins the blade. If it's stable it would be fine to use the sawzall if you feel more comfortable with that tool.

 

[blazin_blazer]

that little 10,000 stokes per minute buzzs right thru sheet metal especially if you have a fine tooth blade..it has a nice clean cut with the right blade and at 10000 spm it doesn't jerk and pull the metal like you would think....i recomend any1 with air to add 1 of these ,..i call it a "buff saw" to their collection it is really nice, again i say , as long as you get the 10,000spm or higher...i had a 5700, it was no comparison

its great for fishmouthing tubing and it cuts pretty heavy aluminum, like i said it has al most retired my cutoff wheels i have a straight 1 AND A 90* 1. my next tool is the nibbler they showed you, they make beautiful cuts up to like 12 gauge, and the 1's i've used worked kike a jigsaw for metal and worked fabulous....its really going to come down to what tools you have available too you...
i do however recomend look for the thread "frame off started" and check out how he did his fenders, thats the nicest, cleanest fender "hack" i've seen...u really cant call it a hack. it looked almost stock when he was thru. kept the wheelwell lip and all looks really good , he even clearanced the inside of the fender without hacking it

 

[AussieK5]

Have a look about 2/3 down the page for the way I did my front fenders. To many pics to bother re-posting.

http://coloradok5.com/forums/showthread.php?t=185001&page=2

 

[blazin_blazer]

yea thats how it should be done!! so hows the rebuild going down there? did you finish before your vacation ran out? you do good work! i would love to have 1 of those right handers up here! k-anything! rhd

 

[AussieK5]

Thanks bloke...I'll do an update on that that thread tomorrow...just about to hit the hay.

 

[muddybuddy]

I cut through both layers with a sawz-all and then welded a piece of sheetmetal to cap it.

i really like how that came out!