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ROCKRIDGE4WD Introduces a NEW Jeep Wrangler JK *led* tail ANOTHER Rockridge4wd Creation!! Spare Tire Carrier Delete Building a Bumper?

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Unread 01-07-2011, 09:25 AM   #1
Rutdigger
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My turn to build... DIY Tube Fenders

After my lift install and 35" tire addition I had a slight rubbing issue at full flex, so I decided I wanted flat fenders. As usual I didn't want to pay the cost for the Bushwackers so decided to make my own.

I cut the template out of the paper and transferred it to the foam board, then to the metal. This piece will be the inside of the fender that the rails are welded to:





Then I bent the tubing to the basic shape of the stock fenders. This is when I realized that nothing on the friggin JK is straight..lol.



Welded to template:



Made the other side to match and began to add supports:



Wrapped in painters tape and cut out sheet metal template:





Transferred cutout to sheet metal and cut it out:



Bondo to smooth out then primed for paint:



1st coat of bed liner:



Installed:









Now I just need to get the rear done..lol.

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Unread 01-07-2011, 09:31 AM   #2
austentatious
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they look great! good job
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Unread 01-07-2011, 09:34 AM   #3
nufga
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x2, still saving up for flat fenders since I don't have the capacity to do what you did.

Also, not to deviate from the topic but is that a fabbed stinger on a stock stubby bumper?
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Unread 01-07-2011, 09:57 AM   #4
Rutdigger
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Originally Posted by ausTJ01 View Post
they look great! good job
Thanks bro!

Quote:
Originally Posted by nufga View Post
x2, still saving up for flat fenders since I don't have the capacity to do what you did.

Also, not to deviate from the topic but is that a fabbed stinger on a stock stubby bumper?
Thanks man...and yes, that is a home brew stinger. I posted a build thread to it just now. Let me know what you think.
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Unread 01-07-2011, 10:09 AM   #5
Mol
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Good chit, I like the kind of backwards flare at the bottom rear.
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Unread 01-07-2011, 10:24 AM   #6
krutj
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Very nice...from start to finish!

Excellent fab. job Bro..
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Unread 01-07-2011, 10:26 AM   #7
Rutdigger
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Originally Posted by molshove View Post
Good chit, I like the kind of backwards flare at the bottom rear.
Quote:
Originally Posted by krutj View Post
Very nice...from start to finish!

Excellent fab. job Bro..
Thanks guys! Hopefully I can get the rear done soon.
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Unread 01-07-2011, 12:22 PM   #8
saharac
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Great job man... great fabrication skills...
saw your thread on rock rails -- thats great too...

I am looking to get a simple set of rock rails, the prices on the brands are ridiculous, hopefully will find a welder in town who does something like the ones you made...

Only critique that I have is for the fenders,, they seem a little short in length to me,, I personally would have liked it to cover more of the inside support thats welded to the rail, probably to the point where the supports curve down again...
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Unread 01-07-2011, 01:26 PM   #9
Rutdigger
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Originally Posted by i_love_my_jeep View Post
Great job man... great fabrication skills...
saw your thread on rock rails -- thats great too...

I am looking to get a simple set of rock rails, the prices on the brands are ridiculous, hopefully will find a welder in town who does something like the ones you made...

Only critique that I have is for the fenders,, they seem a little short in length to me,, I personally would have liked it to cover more of the inside support thats welded to the rail, probably to the point where the supports curve down again...
Thanks man. No worries on your critique bro.. I didn't like how they looked further down (I made a proto type first) so I made mine a little shorter. Thats the beauty about building your own stuff, you can make it look like you prefer..
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Unread 01-07-2011, 02:04 PM   #10
saceone
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I need to buy a welder and take a few courses

sweet build, thanks for posting
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Unread 01-07-2011, 02:10 PM   #11
mclaggan123
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first off great job. second may i ask what you are using to bend the tubing? a pic of your bender would be helpful. thanks
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Unread 01-07-2011, 02:19 PM   #12
Rutdigger
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Originally Posted by mclaggan123 View Post
first off great job. second may i ask what you are using to bend the tubing? a pic of your bender would be helpful. thanks
I'm using this "pipe" bender Harbor Freight Pipe Bender. Now, in order to be able to bend tubing you will ned to make some modifications. I made a few clamp boots that fits over the top of the tubing when bending:





These boots keep the tubing from rising in the pipe boot and kinking.

For square tubing I made this die/boot:







With this I can bend 1" swuare tubing. I added removable shims that allow me to bend 3/4" square tubing also.

The last step is to fill the tubing with sand and tape the ends. This give it a bit more stability and produces cleaner bends.
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Unread 01-07-2011, 05:05 PM   #13
saharac
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Thats the beauty about building your own stuff, you can make it look like you prefer..
Absolutely... Keep it going...
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Unread 01-08-2011, 12:44 AM   #14
Rutdigger
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Originally Posted by i_love_my_jeep View Post
Absolutely... Keep it going...
Yeppers batman..lol. I got some more coming soon!
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Unread 06-22-2011, 09:09 AM   #15
usmc20c
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Rutdigger those fenders look freakin awesome!!! Hope you don't mind but i'm gonna copy yours somewhat but with a little bit of my touch...
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