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Unread 05-29-2013, 10:27 PM   #1
Luuca
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TJ Flares on a YJ (Pic Heavy)

Documented my installation of the set of TJ Flares onto my 1991 YJ. When I searched for this write up, I could find bits and pieces, but no step-by-step instructions. What is presented here is how I achieved this modification. I am sure there are alternative ways and means, but what you see documented here worked for me.

Tools I Used:
  • Compressor - 50 Gal, 80CFM
  • Cut Off air tool
  • "File" air tool
  • 8mm, 13mm ratcheted wrench
  • 8mm open/box end wrench
  • Long flat-tip screwdriver
  • Philips head screwdriver
  • Large vise-grips
  • Medium vise-grips
  • Sharpie Marker
  • Bodywork Hammer
  • Blue Painters tape
  • Krylon satin black spray paint
  • Electric Drill
  • Metal drill bit - same size as existing flare fastener holes
  • Heavy Duty Gloves
  • Eye protection



Front TJ Flare

Step 1: Remove the existing flare.
Using the 8mm ratchet wrench and the 8mm box-end wrench, locate and unscrew the fasteners holding the stock flare to the metal fender.



The plastic fastener backs will rotate once loose, I used my fingers to hold them in place.

If your YJ has the flare extenders installed, there are 3 bolts holding that piece in place. These bolts were 1/2" or 13mm on mine.



You will need a Phillips head screwdriver to remove the side marker lens. Also don't forget to twist and pull the bulb assembly from behind the lens.



Step 2: Prepare the TJ Flare
The stock TJ front flare has two sections that I removed;

The Location Pins - These plastic "crosses" are used on the stock TJ fender to position the TJ Flares. I chose to cut them off rather than cut holes for these on my YJ.



The Fender Edge - This edge slides over the stock TJ Fender, but gets in the way on the YJ.



I used my Cut-Off saw on them both:

NOTE- IF I HAD IT ALL OVER AGAIN, I WOULD HAVE LEFT THE RAIL ALONG THE BACK EDGE OF THE WHEEL WELL INTACT UP TO ABOUT THE CENTER TOP OF THE FLARE. It would allow the top-front section of the flare to sit flush without trimming the top of the metal fender AND allowed a very clean edge when viewed. It would have also better protected the cut portion of the fender.



The back of the TJ Front Flare should now be flat or flush all along the edge and back:



Step 3: Pre-Mounting
In order to better visualize the line where the radius of the fender top meets the flat side of the fender, I laid a piece of blue painters tape along that line to aid in lining up the top of the TJ flare.





Once the blue tape was on, I aligned the front edge of the TJ flare as close to the front curve of my YJ fender as possible.



My experience is that you can not raise the flare high enough on the YJ fender to eliminate an overhang of the TJ flare below the front edge of the YJ fender. It's acceptable.



Once you have the front of the TJ flare in position, use a vice-grip (or clamp if you have one) to hold it in place snug. Then position the rear of the TJ flare along the bottom edge of the YJ fender and clamp it in place with the second vice-grip.



Step 4: Marking the Cut

Using the Sharpie marker, trace the inside edge of the TJ flare onto the YJ fender. Make a solid, legible line. Then remove the TJ flare and vice-grips.
NOTE: If you YJ is a dark color, you'll want to lay painters tape over the area to be cut so that you can better see the Sharpie line.



Step 5: Making the Cut

Using the cut-off saw, wearing heavy gloves and eye protection, carefully cut along the line you marked.



Once this section has been removed, I used the air "file" to grind down the area to avoid any sharp edges coming in contact with tires. A normal metal file would work, just slower.



After that, I taped off the area from over spray and used satin black Krylon spray paint to protect and black-out the freshly cut metal.



Step 6: Mounting Holes

After about 20 minutes, remove the tape, reposition the TJ flare onto the fender making sure to align the front and rear sections as before. Once aligned and clamped on, use the Sharpie to mark the Stock TJ mounting hole points. NOTE: I didn't use all the stock points. I used the stock YJ flare mounting holes for to mount the TJ flare to the front of the YJ fender by marking the hole positions from inside and behind the YJ fender onto the TJ flare, then drilling the holes as needed.

Once the mounting points that need to be drilled are marked, I used the phillips head screwdriver and my hammer to center-punch the drilling locations and drilled them out.



NOTE: The stock rear mounting holes on the TJ flare in the picture above are accessed on the back side from inside the engine bay and under the battery tray.

Step 7: Final Installation

Start final installation by either re-using your stock YJ fasteners, or as in my case, I used a mix of the TJ fasteners (which have large washers on the screws) and the stock YJ fasteners depending upon how much room I had inside the flare well. Both Fasteners use the 8mm ratchet wrench or box end wrench.

I installed from front to rear. The rear Stock TJ fastener holes are kind of a pain to reach under the battery tray inside the engine bay; however, I found that I could get all 3 by either sliding my hand down the side between the metal fender and the tray, or by going under the tray and using vice-grips to hold the plastic fastener.

The finished Front TJ Flare:



---------------------------------------------------------------------------------

Rear TJ Flare

Step 1: Remove the existing rear flare and fender liner.

Using the 8mm ratchet wrench and the 8mm box-end wrench, locate and unscrew the fasteners holding the stock flare to the metal fender.

Under the rear quarter panel of my YJ, there was a plastic liner and cover. I easily removed them by removing the 8mm sheet metal screws and by pulling out 4 plastic fasteners:

Quarter Panel Cover:


Fender well Liner:



Step 2: Prepare the TJ Flare

The stock TJ Rear Flare has two sections just like the front; however, I only removed the Locating Pins on the Rear Flares.

The Location Pins - These plastic "crosses" are used on the stock TJ fender to position the TJ Flares. I chose to cut them off rather than cut holes for these on my YJ. The Locating Pins are smaller on the Rear TJ Flares

The Fender Edge - This edge slides over the stock TJ Fender, and after the cut is made to the rear YJ fender, it also slides over the YJ fender perfectly. I chose to leave it on to cover any sharp edges from the cut.

Step 3: Pre-Mounting

Clamp the curved edge of the TJ Rear Flare onto the leading edge of the YJ rear fender using a vice-grip about 1/4 of an inch inside the factory line. Because the TJ flare is larger, you will need to cut the entire circumference of the fender opening for a proper fit.



Step 4: Marking the Cut

Using the Sharpie marker, trace the inside edge of the TJ flare onto the YJ fender. Make a solid, legible line. Then remove the TJ flare and vice-grips.

Because the TJ Rear Flare I used still had the EDGE on it, I drew a second line above the first to accommodate the edge on the flare.



NOTE: If you YJ is a dark color, you'll want to lay painters tape over the area to be cut so that you can better see the Sharpie line.

Step 5: Making the Cut

Using the cut-off saw, wearing heavy gloves and eye protection, carefully cut along the UPPER line you marked to account for the TJ Flare Edge.

Once the metal cut, your rear panel will look like this:



The section removed is was about 2.25" at it's widest, and about 1.4 inch at it's narrowest for my modification.



As with the front fender cut, I taped off the area from over spray and used satin black Krylon spray paint to protect and black-out the freshly cut metal.

Step 6: Mounting Holes

Reposition the TJ Rear Flare onto the fender making sure to align the front and rear sections as before. Once aligned and clamped on, use the Sharpie to mark the Stock TJ mounting hole points. NOTE: I didn't use all the stock TJ mounting points. I used the stock YJ flare mounting holes along the front of the rear TJ Flare by marking the hole positions from inside and behind the YJ fender onto the TJ flare, then drilling the holes as needed.

Once the mounting holes are marked, remove the TJ rear flare, center punch the marks, and drill them out. With the liner still installed, some of the mounting holes along the top edge and back edge of the TJ flare will need you to drill through the liner as well.

Step 7: Final Installation

Start final installation by either re-using your stock YJ fasteners, or as in my case, I used a mix of the TJ fasteners (which have large washers on the screws) and the stock YJ fasteners depending upon how much room I had inside the flare well. Both Fasteners use the 8mm ratchet wrench or box end wrench. I installed from front to rear.

The finished Rear TJ Flare:




Side Marker Lights

The side marker lights on my YJ were not long enough to reach the TJ Flares side markers. I had to cut and extend these wires to reach the mounting holes. I used some extra wire i had laying around, soldered the connections and used heat-shrink tubing on the connections. I also used some extra split loom I had to cover and protect the wires.

One other notable difference was that the bulb socket on the side markers on the YJ had 4 points while the TJ side marker lens only had 2 points. I simply took out my pocket knife and trimmed two of the YJ points off (opposite each other) and installed the bulb socket into the TJ Lens assembly.


ALSO: It helps A LOT to have your son driving his remote control Jeep around you, over you, and constantly bumping your sides and head as you work.



Hope this helps!

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Unread 05-29-2013, 11:54 PM   #2
Carlos14
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Very nice write up. This should help many.
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Unread 05-30-2013, 04:55 AM   #3
Kdeome
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That's the first I've seen/heard of the rear flare overhanging?
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Unread 05-30-2013, 09:24 AM   #4
StanF
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Quote:
Originally Posted by Kdeome
That's the first I've seen/heard of the rear flare overhanging?
Doesn't it depend on how high you mount it and how much trimming you do? The OP mostly trimmed the back of the opening, and not the top.
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Unread 05-30-2013, 09:30 AM   #5
Luuca
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Quote:
Originally Posted by Kdeome View Post
That's the first I've seen/heard of the rear flare overhanging?
I modified the original write up with how I fit the TJ flare to the rear of my YJ and my reasoning for doing so. I'm not 100% sure I did not do something wrong as I was kinda figuring it out as I went, but I am 100% sure that the way I have it mounted offered the most clearance towards the rear of the opening.

Maybe someone else who has installed the Factory TJ Rear flares could chime in with their results, direction for mounting, and if they had any overhang or not. I'm interested to see where I went wrong.
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I only get 100 characters including BBcode for my Sig line now so I thought I'd be witty and write until I run out of characters but for some reason I'm not running out of space as if some magic or witchcraft is afoot. I wonder what it could be. Perhaps the planets aligned and I'm the exception to the rule or some benevolent soul in a position of authority has looked down upon me and my predicament and has opted to rectify it in his intoxicated state and make people read this whole thing for no reason at all. Other than his amusement of course.
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Unread 05-30-2013, 09:40 AM   #6
johnboy68
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I kept the lip on my rear flares like you did Luuka. But mine are flush with the tub front and rear of the wheel well.

I cut all the way around the radius of the opening but cut most at the rear. There is only about 1/4" up front that you can cut and not cut into the inside of the tub.

Like this:





Hope this helps...
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Unread 05-30-2013, 04:47 PM   #7
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Originally Posted by DirtKar View Post
You did a great job, thanks for the write up!
As for the piece that's exposed, if you weren't hitting it before there's no reason to think you're suddenly going to start hitting it now. It's a cosmetic concern for you at best. Move into some bigger meats and it's a different story... Looks nice.
Sorry didn't mean to make it sound like he was going to contact it with his current set up. But with larger tires that area becomes a problem.





I'm lucky I didn't shred my tire on that after it happened....

Anyways, awesome write up, clean work, way to go!
Oh and my TJ flares hang down just a bit in the back too. I think it looks fine

Cheers
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Unread 05-30-2013, 04:51 PM   #8
Luuca
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Quote:
Originally Posted by johnboy68 View Post
I kept the lip on my rear flares like you did Luuka. But mine are flush with the tub front and rear of the wheel well.

I cut all the way around the radius of the opening but cut most at the rear. There is only about 1/4" up front that you can cut and not cut into the inside of the tub.

Like this:





Hope this helps...
That's a perfect picture of what I was trying to comprehend. I'm going to re-do my rear flares tonight by following your style of cut. My only concern is the mounting holes along the front edge. How did you mount the front side? Did the screws and fasteners cause issues?
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I only get 100 characters including BBcode for my Sig line now so I thought I'd be witty and write until I run out of characters but for some reason I'm not running out of space as if some magic or witchcraft is afoot. I wonder what it could be. Perhaps the planets aligned and I'm the exception to the rule or some benevolent soul in a position of authority has looked down upon me and my predicament and has opted to rectify it in his intoxicated state and make people read this whole thing for no reason at all. Other than his amusement of course.
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Unread 05-30-2013, 05:43 PM   #9
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Looks good. I wanted to put TJ flares on but I don't want my tub to rust from being cut.
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Unread 05-30-2013, 06:35 PM   #10
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Quote:
Originally Posted by Campsen
Looks good. I wanted to put TJ flares on but I don't want my tub to rust from being cut.
What's keeping your tub from rusting now? Paint.

Primer and paint the exposed metal once you cut.

Sent by my pretentious iPhone.
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I only get 100 characters including BBcode for my Sig line now so I thought I'd be witty and write until I run out of characters but for some reason I'm not running out of space as if some magic or witchcraft is afoot. I wonder what it could be. Perhaps the planets aligned and I'm the exception to the rule or some benevolent soul in a position of authority has looked down upon me and my predicament and has opted to rectify it in his intoxicated state and make people read this whole thing for no reason at all. Other than his amusement of course.
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Unread 05-30-2013, 06:35 PM   #11
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Originally Posted by Campsen View Post
Looks good. I wanted to put TJ flares on but I don't want my tub to rust from being cut.
Cut it, paint it and call it good.
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Unread 05-30-2013, 10:14 PM   #12
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Quote:
Originally Posted by Luuca

... Did the screws and fasteners cause issues?
Glad it helped. No issues. I have one screw inside the tub, but its between the roll bar and the wheel well so it's not noticeable.

I used 1" self drilling sheet metal screws.
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Unread 05-31-2013, 08:38 AM   #13
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I just took my TJ flairs off after running them 10 years. I put TAG YJ flairs on and looking for the screw for the marker light. Can you post a pick? As for the rust I rattle canned the cut edges and holes and had no rust at all. Good job on the flairs bye the way.
light.jpg  
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Unread 05-31-2013, 09:40 AM   #14
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Well done!!
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Unread 05-31-2013, 10:54 AM   #15
Luuca
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Quote:
Originally Posted by Dake View Post
I just took my TJ flairs off after running them 10 years. I put TAG YJ flairs on and looking for the screw for the marker light. Can you post a pick? As for the rust I rattle canned the cut edges and holes and had no rust at all. Good job on the flairs bye the way.
The screw in the image you posted is of the Stock YJ Side Marker. I'm not 100% sure they are the same screw as the TJ Flare Side Marker. I will remove one of the TJ flare screws and get a good image of it for you tonight or tomorrow.
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I only get 100 characters including BBcode for my Sig line now so I thought I'd be witty and write until I run out of characters but for some reason I'm not running out of space as if some magic or witchcraft is afoot. I wonder what it could be. Perhaps the planets aligned and I'm the exception to the rule or some benevolent soul in a position of authority has looked down upon me and my predicament and has opted to rectify it in his intoxicated state and make people read this whole thing for no reason at all. Other than his amusement of course.
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