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Unread 10-19-2010, 10:51 AM   #1
CTJeepWJ
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My Cheap Flat Flare project

I posted this under the TJ forum, but maybe it could help others looking for some cheap flares.
Here is the link to the original post: http://www.jeepforum.com/forum/f9/pr...lares-1116343/


Well like most people, I don't have the cash for flat fenders or flat flares. I like the look, but I also like being a little creative. I know this isn't a new idea, but I figured I would try to document my little project to hopefully help others.

What you need:
-Extended flares (6" or 7"). I have seen them for 150-200 bucks, got mine used for $80 on Craigslist. This can also be done on factory flares but I wanted to have the tire coverage for a variety of reasons.
-Pencil or wax pencil (recommended)
-Jig saw with fine tooth blade (recommended)
-Ruler or tape measure (recommended)
-Straight edge for drawing long/straight lines (recommended)
-Masking tape (optional)
-Utility knife with new/sharp blade (optional)
-Sand paper or sander (optional)
-Cardboard for making a template (optional)

Here are some pictures of my flares before I got started.




So next I used a ruler, straight edge and a wax pencil to mark out my general cut marks. Since I have a sweet, old Trail Ready bumper, I wanted to incorporate the angles of the bumper into the flares. You can also use masking tape to mark your cut edge, masking tape is repositionable so you can rework your projected cut marks easily. I ended up cutting off about 2 inches up from the bottom of the flare.




After finalizing my cut line, I used my jig saw to make my initial cuts. I have seen some people use a razor blade and make several light cut mark until you get through the flare. I thought the jig saw was better for me. It is up to you of course.




I took some measurements and picked an angle to clean up each end of the flares and made those cuts to my liking. I actually create a little template out of some cardboard and transcribed the angles onto the flares so they were all equal. On the last picture you can see the front flare cut to match the angle of the front bumper.




My final step was to use the attachment on my Black & Decker mouse sander to take of the sharpness of the flare edge. You can do this with a file or a sanding block but the sander made the job quick and easy and helped to straighten out any waviness in my cut line. Here is the final job. I am currently trying to figure out a solution for the side marker. For now, I have taken the right one and put it on the left side (and vise versa) and attached them under the flare with some industrial strength velcro. Seems to be working so far, I may switch them back to the correct side or make a little bracket or something.




Total time about 2 hours from start to clean up. I was patient because I am anal, so I wanted to do the cleanest job possible.

Hopefully this helps someone out, let me know what you think!

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Last edited by CTJeepWJ; 10-20-2010 at 09:14 PM.. Reason: fixed pictures
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Unread 10-20-2010, 12:18 PM   #2
redmater06
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I like the post and cleanliness and the neatness of how you did it. I might do the same thing with my flares.
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Unread 10-20-2010, 02:08 PM   #3
CTJeepWJ
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Hey thanks redmater, glad to help. Hope it works out for you! Let me know if you have any questions or run into any issues.
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Unread 10-21-2010, 09:14 PM   #4
karlo
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The edges look smooth. Great job!
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Unread 11-09-2010, 11:34 PM   #5
tealo951
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Unread 11-22-2010, 02:13 AM   #6
smkoehler82
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^^^^^ Like how ya kept the side markers looks awesome!
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Unread 11-22-2010, 04:04 PM   #7
djflyy
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Quote:
Originally Posted by smkoehler82 View Post
^^^^^ Like how ya kept the side markers looks awesome!
Ditto. Looks great!
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Quote:
Originally Posted by bmosing View Post
Cleaning this thing up is similar to a slightly abused pornstar throwing on a bunch of makeup to try to hide her eternal scars, but I think she doesn't look too bad
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Unread 11-23-2010, 01:29 AM   #8
tealo951
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Quote:
Originally Posted by smkoehler82 View Post
^^^^^ Like how ya kept the side markers looks awesome!
Quote:
Originally Posted by djflyy View Post
Ditto. Looks great!
Thanks! I also used a jigsaw. Took 1.5in off all the way around the rears, and the top and back of the front flares. The front of the front ( haha ) flares i just eye balled when i drew the lines out. easy hour or so project. even had time to do my buddies rear flares too.
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Unread 12-03-2010, 03:16 PM   #9
Cjensenr
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I for the life of me do not get the point of chopping a good flare apart. Lol!

C.
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Unread 12-04-2010, 07:21 AM   #10
tealo951
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Originally Posted by Cjensenr View Post
I for the life of me do not get the point of chopping a good flare apart. Lol!

C.
when the jeep flexes, since my tires are over sized, they rub on the lip. I'd rather have more room then risk my flares being chewed up by my tires. And i (no offense) hate the wider flares with an undying passion, plus they're expensive and i don't want to buy them. Make sense now?
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Unread 12-13-2010, 12:41 PM   #11
joec2528
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flat is the way to go, nice work and cl p/u
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Unread 07-24-2012, 09:22 PM   #12
Sdavidf
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I got sick of cleaning mud out of the dash and interior of my TJ, even though I never go looking for mud it always seems to be in the way and since going with wider tires it has always found its way into the cab. But unfortunately like most of us I didn't have the cash for flat flares and I hate the look of extended flares. I found your post and was able to trade my stock flares even for a set of extended flares on Craigslist. I just wanted to say thank you and post some pics of the almost completed project.

The only thing I would add to your description is that I found it difficult to get a good line measuring from the end of the flare. So I measured out from the body and found that much easier.

I still plan to pull them off and shoot them with a coat of truck bed liner. And maybe add rubber edge trim (like people use to protect the edge of their doors) around the edges to give the appearance of tubes. That is if I find the right stuff at the right price.

Thanks for the great write up.
image-550983940.jpg   image-3038191147.jpg  
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Unread 07-25-2012, 07:28 AM   #13
CTJeepWJ
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Glad you found it helpful, yours came out great, nice rig. The only thing I would do differently (if I were to do it all over again) would be to cut off a little less on the front flairs. Mine sag a little bit in the hot sun and I think if I were to cut off a little less, the outside curve of the flair might have held them up a little bit better. I also have to find a better/more permanent solution for my side turn signal. Double sided tape and industrial strength Velcro just don't hold long term.
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Unread 09-08-2012, 07:33 PM   #14
PeejPilot
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quick question: what size tires/ lift do you have on your rig CT? i have a 2in with 31's and am considering doing this to gain enough clearance to tuck 33's? i have the pocket style flares on mine and it appears that there is alot of room to be gained with a flat fender that would allow bigger tires and eliminate the problems with bigger lifts
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Unread 09-08-2012, 10:04 PM   #15
CTJeepWJ
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I have a 2 inch lift and 31s.
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