I just did this... all welded lips.. used 1/2" round rod...
Ill try to shoot some pics for you tomorrow... it was pretty easy... used a mig wire called "easy grind" specifically for bodywork in .023 and softer than other wires.. a little body hammer work... but I can weld and have the right equipment
the added benefit... the fenders are stonger than stock without any more weight,,, and they look stock with a large opening that makes you look twice,,, if youre a ck'r you know theyre modified... if you dont know our trucks they look stock...
I opened them all the way up to where the lip meets the fenderwell... used a plasma, a cutoff wheel and a sawzall
I have a couple of hours per fender in them before bodywork,,, so I would say a bodyshop would bone you at least 500 per fender.. heck you cant go in a bodyshop for under 500 bucks today... unless its earl scheib... and would you want that bodywork monkey making fender flares out of bondo for you?
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