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Well, Big Ugly's officially a project and not a vehicle

I use 5" x 3/32" thick "Zip-Cut" disc's. Trace out the cut lines with a sharpie on some masking tape. Cut close to the line, then use a flap wheel sanding disc to smooth and fine tune the trim right to your line.

Paint the rims black...that silver just looks really out of place with the olive drab CARC paint.

Rene
 
Rene...You should try out these Sait .045 cutting discs. We use them at work, alot of ornamental iron so we go through aloooot of them. They cut fast enough that on materials less than 1/4" and cuts shorter then a couple inches, it's usually faster to use one of these then to use the chop saw or shear.
http://www.amazon.com/SAIT-23105-6-...-3160610?ie=UTF8&s=hi&qid=1190572623&sr=1-313

Oh yeah...might as well add this too. If you want the best angle grinder money can buy, take a look at some of the Metabo stuff-

http://www.metabousa.com/metabo/handgefuehrte/us/en/produkte/

Check out this one-
http://www.metabousa.com/metabo/han...grinder/anglegrinderwe14125vs_6_01426_42.html

5", variable speed 3500-10500rpm, overload protection, soft start, torque limiting clutch, 12amp motor. 12 amps!! I just ordered myself one...$200. :D
 
Flap wheel sanding disc eh? Already had figured on the tape and having to clean it up but the sanding disc sounds like a good idea.
Do you guys use an angle grinder or a cutting wheel like I was thinking? I have both.


The wheels definitely aren't going to end up OD green, or any kind of green. Didn't like the look of the green ones it had before. I think I might just do black...not to mention the first thing the wife said last night was "are you going to paint them black?":tongue1:
Just gotta bring myself to sand and paint them now...
 
KidJethro said:
Rene...You should try out these Sait .045 cutting discs. We use them at work, alot of ornamental iron so we go through aloooot of them. They cut fast enough that on materials less than 1/4" and cuts shorter then a couple inches, it's usually faster to use one of these then to use the chop saw or shear.
http://www.amazon.com/SAIT-23105-6-Inch-045-Inch-8-Inch/dp/B000FEDVNY/ref=sr_1_313/103-5595693-3160610?ie=UTF8&s=hi&qid=1190572623&sr=1-313

Oh yeah...might as well add this too. If you want the best angle grinder money can buy, take a look at some of the Metabo stuff-

http://www.metabousa.com/metabo/handgefuehrte/us/en/produkte/

Check out this one-
http://www.metabousa.com/metabo/handgefuehrte/us/en/produkte/anglegrinder/anglegrinderwe14125vs_6_01426_42.html

5", variable speed 3500-10500rpm, overload protection, soft start, torque limiting clutch, 12amp motor. 12 amps!! I just ordered myself one...$200. :D
Click to expand...

We use the 1/16" x 5" Walter zip cut disc's at work. I've tried the Sait stuff and didn't like them in comparison. I recomended a 3/32" thick disc just because they're a little less likely to shatter/break/explode than the thinner stuff.

The Metabo grinder looks good. Might have to see about ordering a few for our shop. We have the Makita's right now...and they've been good. The soft start and variable speed are both nice features though.

Rene
 
AJMBLAZER said:
Flap wheel sanding disc eh? Already had figured on the tape and having to clean it up but the sanding disc sounds like a good idea.
Do you guys use an angle grinder or a cutting wheel like I was thinking? I have both.


The wheels definitely aren't going to end up OD green, or any kind of green. Didn't like the look of the green ones it had before. I think I might just do black...not to mention the first thing the wife said last night was "are you going to paint them black?":tongue1:
Just gotta bring myself to sand and paint them now...
Click to expand...

I used the zip-cut disc on a 5" angle grinder (with the guard removed...:whistle: )

Rene
 
Where I work is also a Harris Industrial Gases outlet place. Dealer for the Metabo stuff. Great company...Our Metabo rep is great about getting grinders fixed/repaired/warranteed, or whatever. :) They don't really squawke to much about warantee stuff...and we abuse the shiiit out of our grinders. :eek1:
 
Local ACE had nothing good for me. Lady looked at me funny when I said I was cutting the sheet metal of a truck fender. Try the bigger places tomorrow.
Damn livin' in the sticks...


If I just cut off the corners of the fenders are any of them double skin? In other words am I going to have to worry about some of it seperating or having to be welded back together?
 
Any new pics? I am thinking about to do the same thing to my M1008, 38" XLs and no lift. Yours is looking good.
 
Nothing much. Started cutting up the rear fender yesterday. Still gotta do the rest of the fenders and move the front axle forwards.
The front axle movement isn't necessary but should make the trimming required small and fix one of GM's design oddities.

364830_194_full.jpg


364830_195_full.jpg


364830_196_full.jpg


I was just going to nibble the edges off but figured...eh, do it all at once.
 
Sweet! Looking good. I wish mine had nice CARC paint on it like yours.
 
How is the XL fitment going?

You inspired me to get off my butt and see what mine will look like. I got two mounted yesterday and put them on the front with a little help from a sawzall and a grinder:D For me there is no way around moving the axle forward. It is real tight in there and I can't get a full turn out it now. I'd rather do that than cut up the inner fender. Have you tried your zero rates yet? I think I will order some and see what that will gain me. I like it so far but I also think 4" springs would be nice but don't want to spend the money.

Here's what mine looks like.
IMG_0308.jpg
 
I've got the zero rates in but found you can't move the front axle forwards without a longer front driveshaft. So being the poor bastard I am I just used them as 1" lift aal's.
Not sure if more cutting will be needed yet as I've had some issues along the way but the suspension is all done and the draglink has been rebuilt, just trying to figure out the ORD steering brace now.

Here's the only proof I have so far that any real changes have been done:

DSCN1150.JPG
 
Well crap....I am trying to go cheap and driveshaft mods is just more money. Can you steer it lock to lock with the aal's and cutting you have done? Mine hits pretty bad at the back of the inner well. Did you use the aal's in the back too or just the front?

I really don't want to cut much more but 4" springs, steering arm, shocks, maybe extended brake lines,and driveshaft mods all add up quick.

And thanks for posting...good info!
 
Just the front. In the rear the tires almost fit with the untouched fenders. I was just going to nibble the lower edges but then the grinder talked me into going full hog.

The place I got mine from had trimmed the very bottom lower edges of the wheel wells just a little to make the HMMWV 36's fit. The guy who gave me this idea said he only had to trim back to the fender liners to make his fit and he didn't do any suspension mods.
I'm waiting to see what I have to do. Debating getting the clean up/painting done and then aligning it or just having it aligned and then finishing the paint stuff afterwards. Need to get my Tracker off the road but don't want to end up redoing the Chassis Saver.


Part of the problem with the 4" lift is that the springs will invariably be softer so you'd get more flex and then more potential for hitting so you'd have to trim again...so I'm just going to make them fit now.
 
Okay, got the rears on and on the ground and they look like they should be good.

I have the driver's side tire on and have turned it through it's entire arc and it looks to clear the fender nicely. Luckily 1 ton springs don't flex like super soft half tons or just worn springs.

Yeah...the tire will still hits the draglink but not as bad. You're definitely going to need to go get a longer 3/8" fine thread bolt (I think that's what it is...but I'll know for sure tomorrow) to replace the factory d-side steering stop. I had a 2" long bolt in there to stop the rubbing with the HMMWV tires but now it's too long and the 1" long factory bolt is too short. Going to go get 1.5" and 1.75" long bolts tomorrow and see which one works.
 
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