guys that cut out rear fenders, how did you fill the gap?

[Berrett]

for people that have cut out their rear fenders, what did you do to fill the gap between the 2 pieces of sheet metal (inner and outer). i have had mine cut for a long time and just left the huge opening untouched but don't really like it like that cause it lets mud and crap get inside. so lets hear some ideas and see some pics of what people have done. i know i could just weld some sheetmetal in there but i hate welding thin stuff like that so i am looking for other ideas

[PlumCrazy]

Rumor has it some have used that expanding foam...I have not cut fenders but filled gaps when installing my garage entry doors and it works great for that.

[Berrett]

i have thought about stuff like that but those rear quarters are always getting smashed up so after a couple hits/dents i would think it wouldn't hold the foam anymore (if i never hit back there i would, but i always hit them off road)

[PlumCrazy]

Not sure but the foam gives a little without breaking. Besides 4 bucks to try never hurt, the only thing you lose is some time. Use some duct tape to tape some plastic up on the inside, spray it and pull the plastic toward the out and tape again.

[ November 18, 2003, 01:45 PM: Message edited by: PlumCrazy ]

[blt2krl]

Here is how I did mine. I used seam sealer to seal it all up.
TRIMMING FENDERS (http://www.cfsja.org/tech/fender.html)

[River Beast]

I laid duct tape over the gap on the outside... then back filled with foam on the inside...... covered outside after dry with clear silicon.... still there since 98

[bigun]

sheet metal?

[robselina]

I search around a couple of weeks ago and expanding foam seems like the winner. I've picked up a couple of cans and intend to give it a shot. I'm probably going to try to fill the entire fender since I get some rattles back there and I figure it isn't doing any good staying open...

[Berrett]

thanks blt2krl, that was the kind of thing i was looking for. like i said foam looks good for street rigs, but if you keep hitting/bending the rear quarters i don't see it working out too well

[Manhattan]

I just cut my fenders. I filled the gaps with Great Stuff. I ruled out Bondo - it will crack and fall out with the first contact with a tree or rock. Ruled out sheet metal - too much work. Ruled out edge molding - wouldn't stay on.

The foam was easier than you could imagine. I didn't use any backing. I just sprayed it in and waited several hours for it to fully expand and dry. Tip: Use a long razor blade and slice of the excess - don't let the tip of the blade out of the foam.

It looks great - solid. I've just got to paint it... it's yellow.

[Rockwagon]

When I cut mine I left the inner fender long, cut slits in it, beat it with a hammer to meet the body, than miged it together.

[Merc69]

Simmilar to Rockwagon. Cut out hafl the way that you want to trim. Then make slits up to where you want to trim to. Then bend in and weld closed. Grind the welds smooth and you are good to go. Also you need to seal the areas inside where the weld burned off the paint.

I have pics but there are others out there that have done as well or better.

I trimmed a total of almost three inches out of the fender on PsyOp. Looks good.

[Tad]

http://members.cox.net/chmsawsroofracks/fencutrear.JPG

[The BEAST]

great stuff for 2 years no problems so far

[Michael]

Did mine like Tad. 1" Wide strip of sheet metal. About 8" or so long. Welded the inner to the outer. Grinded the outside edge smooth to match the body. Took about 4 hours per wheel well. And water tight. Perfect finish. Pics are in my sig.
http://f1.pg.photos.yahoo.com/ph/mjbhayes/lst?.dir=/Fender+Trimmin&.src=ph&.order=&.view=t&.done=http%3a//f1.pg.photos.yahoo.com/

[ November 21, 2003, 07:37 PM: Message edited by: Michael ]

[Serious Johnson]

Expanding foam like "GreatStuff" is hydrophilic (a faincy term for gets wet and stays wet), and can greatly increase the likelihood of rust. I've worked on houses in very humid climates that had rot where wood touched foam with no direct leaks. The type used in boats is much more expensive, but is generally hydrophobic (another faincy term, roughly translated as "shies away from water"). Some of the sporty-type racecars use stuff still more expensive that adds structural strength. For this sort of thing it's imperative to chemically clean the metal so that the foam can bond.

:-

[fulsizjeep]

Here is what we did...
Trimming Wally's Fenders - Feb, 2003 (http://www.frontier.net/~mystkblu/wallytrim/)

[Stuka]

Ok not sure why I didnt see this post, but here is my trim. I anted 1.5" or so gone, so I cut off 0.75", then folded over the inner and outer layers together into the inside.

These picts are when I had 31's on it (tire looks tiny)

BTW: that little part that sticks down a bit along the top edge is because of a little fold thing on the inside from the factory, wasnt able to fold all the way up. And that front edge by the rocker is straight, but its very dented so it makes it look like it isnt.
http://tribal.org/~brandon/ifsja/fender-trim/pass-rear.jpg

http://tribal.org/~brandon/ifsja/fender-trim/inner-folding.jpg

[ November 23, 2003, 12:08 PM: Message edited by: Stuka ]

[Damage, Inc.]

I cut mine then with 3" strips of sheetmetal, set them up inside the wheelwell and welded them. The inside weld is tough (read IMPOSSIBLE), but it turned out good and looks even better.

I did this because I was thinking of putting on those JCW 5" flares...

I can post pics if ur interested in this type.