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Fender Hacking Method...

i used the method that i believe is described in our tech section...cutoff wheel on the outer metal because of the control. then a saws all on the inner metal since it doesn't have to be as pretty, and the inner part of the fender can be tough to reach with a cutoff wheel.
 
I use my air die grinder with a thin cut off wheel. a cheep die grinder and an air compressor thats is not up to snuff will take a bit of work, but I have a big compressor and a bad ass air die grinder that kicks ass. its fast and not as bulky as a 4.5 angle grinder is to use.
 
a guy I wheel with bought steel brake line and bent it to the shape of his cut fenders and welded it on the edge. keeps it from cutting things and stiffens the fender.
 
Dont mean to jack your thread but has anyone tried rolling the edge of the fenders at all? I dont want to end up like spoolnaround over there. I could see myself doing the exact same thing. Also you guys ever notice how many kids walk up to your truck and have to touch the tires? I would feel really bad if some kid ran his hand down the edge of my fender and sliced his hand open.
 
Cut off wheel here too, and I made a template for the 'new' fender opening shape.

IMG_0033.jpg


Rene
 
i didnt roll my edge.. i just cut my fender basically back to the fire wall.. and then i bent my inner fender all the back back to the fender.. filled in the gap between the 2... and welded it up and ground it all smooth.
 
Confedneck79K30 said:
So what's the cleanest/easiest way to hack the fenders? Die grinder with cutoff wheel? Sawzall? Jig Saw??

Just wondering for when i get the new cab and fenders on, so i can hack them up...


Your a Snappy guy, go out to the truck and snag an air nibbler... I'd bet they do a way nicer job than anything else, with no clean up... It's probably what I'll use... I doubt my air shears will work due to the curved surface, but the nibbler should work killer... I use them extensively on bodywork...

21408.JPG
 
i dont own an air compressor, my house doesnt have a garage... but i will probably end up taking it to the 4x4 shop i sell to and let them do it with their plasma cutter, their fab guys are pretty talented..., but the question remains, how to roll the edge? should i leave 3/4" extra, cut a dash in the corners and roll it in, then weld that flap back together?
 
Well, the issue you'll have there is hammer and dollying, bending that lip because of the curve to it. Not so much what you do with the slitted lip after, but getting the radius to the bend.

You would be better off just cutting it clean to the lip you want. Then welding another piece for the lip.. That way you can curve the lip to match the curve of the fender..

Years ago we used to get these patch strips for rust repair, I'm racking my brain trying to remember what they are called. They are basically just a piece of angle sheetmetal, about an inch on each side, with slits cut all the way up it on one side. They would be real easy to use in that way.. trim the slitted side short to fit behind the fender lip, bend piece to fit, clamp in place, mark tab locations, remove and drill holes or use a flange/punch tool on fender lip, reclamp, poormans spotweld it on, then mig the edge..

Personally, I think the easiest, best way for the average joe to do it is the, bend a rod to fit the edge and weld in place idea..

When I do mine, I actually plan to resection in my cutoff lip higher up, adding the patch piece in the middle to fill the dimension you lose... iirc, that is the method also used by someone on here with a first gen. Might have been VTblazer (?), the dude starting his own first gen bodyshop... maybe he'll chime in..
 
ryoken said:
Well, the issue you'll have there is hammer and dollying, bending that lip because of the curve to it. Not so much what you do with the slitted lip after, but getting the radius to the bend.

You would be better off just cutting it clean to the lip you want. Then welding another piece for the lip.. That way you can curve the lip to match the curve of the fender..

Years ago we used to get these patch strips for rust repair, I'm racking my brain trying to remember what they are called. They are basically just a piece of angle sheetmetal, about an inch on each side, with slits cut all the way up it on one side. They would be real easy to use in that way.. trim the slitted side short to fit behind the fender lip, bend piece to fit, clamp in place, mark tab locations, remove and drill holes or use a flange/punch tool on fender lip, reclamp, poormans spotweld it on, then mig the edge..

Personally, I think the easiest, best way for the average joe to do it is the, bend a rod to fit the edge and weld in place idea..

When I do mine, I actually plan to resection in my cutoff lip higher up, adding the patch piece in the middle to fill the dimension you lose... iirc, that is the method also used by someone on here with a first gen. Might have been VTblazer (?), the dude starting his own first gen bodyshop... maybe he'll chime in..

Definitely post pics when you do yours, that will look really clean if you section it like that. When I was looking at cutting mine I would have liked to section that area but I dont have near the experience to do that kind of body work. Ehh, maybe someday. However thats what I think I will do, if you remember the name of that strip or anyone else knows post up. My pops probably knows what that stuff is called, he has alot of body working experience too.
 
Yeah, if you had a fender off you could work the lip in a shrinker/stretcher machine probably to really get a nice lip, but thats pretty advanced stuff.. I have no experience using one, only understand the principals behind it...

I'm looking around right now for that strip panel... Google isn't being my friend tonight... :doah: :haha:
 
i used a sawzall for a short time of it, it pushed and pulled at the lip and looked bad. Pulled out a 4.5" harbor freight grinder with a cutoff wheel. 1 wheel lasted the hole time. Very clean cut, and pretty quick too.
 
I cut through both layers with a sawz-all and then welded a piece of sheetmetal to cap it.

rockslider.jpg
 
ryoken said:
Your a Snappy guy, go out to the truck and snag an air nibbler... I'd bet they do a way nicer job than anything else, with no clean up... It's probably what I'll use... I doubt my air shears will work due to the curved surface, but the nibbler should work killer... I use them extensively on bodywork...

21408.JPG

Have Nibbler and Shears. Will probly try the nibbler but the Plasma is just waaay cooler to play with!!! :saweet:
 
blazin_blazer said:
i bought 1 of these and love it....

http://www.sears.com/sr/javasr/product.do?cat=Compressors+%26+Air+Tools&pid=00919668000&vertical=TOOL&subcat=Automotive+Air+Tools&BV_UseBVCookie=Yes

it cuts thru sheetmetal like a hot knife thru butter, if you use a fine enuf blade and you can get rougher blades and i've cut 1/4'' with it.

its the only 1 i found that has a 10,000 stokes per minute, ingersol and all the other brand names ony have like a 5000 spm. i cut all kind of stuff with mine, couldn't live without, now that i've had it for 7-8 months, absolutley love it...

i have all types of blades with fine teeth per inch to rough blades for thicker stuff, and every tooth count between...i'll say again i love it, its just about put my cut off wheel out of business! right blade and it makes beautiful cuts!

I used this one and had to go back with file to smooth out the edges http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=113
and masking tape to mark where I wanted to cut and protect the paint on the fender that did not get cut off and remember to wear safety glasses, trust me you don't want to get any metal shavings in your eye :D
 
trailblazr81 said:
Have Nibbler and Shears. Will probly try the nibbler but the Plasma is just waaay cooler to play with!!! :saweet:

Yeah, no access to plasma here.. I used to use them extensively from the mid 80's to early 90's, but haven't played with one in probably over a decade...

Wraenking is supposed to be hooking me up with one for my big floor/battery tray project I'm trying to put together... Could save me days with a cutoff wheel...

Haven't really priced em recently, but it seems they're still rather pricey...

I do love those nibblers tho.. Got em for a steal on the bay at $100 new...
 
yea that air saw is tiny its not like a big sawzall...i used it buzzed aruond the fender until rear bottom edge was even with inner fender, i just pushed it in and weldelded it together.

i'm looking for another set of fenders so i can cut them like the guy from downunder showed in his frame off thread, he cut all the way back and retained his wheelwell lip also, i wish he would post up some new stuff on that right hand drive k-5, i really was enjoying that thread...talk about getting the double take. i wonder how much it would cost to ship 1 of those back across the pond. and how hard they are to come by down there.
 

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