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Tech & Fab
Front Fender Trimming on a Suzuki
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<blockquote data-quote="Drone637" data-source="post: 943977" data-attributes="member: 16725"><p>Just thought I would throw together what we have hacking on in the shop the last few days. <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite1" alt=":)" title="Smile :)" loading="lazy" data-shortname=":)" /></p><p></p><p>The problem: The tires were rubbing the fender way to much once my springs broke themselves in a bit.</p><p></p><p>Original Solution: Actually put bump stops back on the SJ.</p><p></p><p>Solution we went with: Getting rid of a decent chunk of the fender. <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite8" alt=":D" title="Big Grin :D" loading="lazy" data-shortname=":D" /> We wanted to keep a somewhat stock look with the full fender, so we went a slightly different route then most flat fender style conversions.</p><p></p><p>First, take on Suzuki SJ</p><p></p><p><img src="http://lh5.google.com/Drone637/RoNGinUzSSI/AAAAAAAAACM/eVS25EUgY0g/s288/CIMG1263.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Draw a line about where you want the new fender line to be.</p><p></p><p><img src="http://lh3.google.com/Drone637/RoNLXHUzShI/AAAAAAAAAEE/GJbYQ1aPw8Q/s288/CIMG1264.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Ignore that line and just cut wherever you think looks good.</p><p></p><p><img src="http://lh3.google.com/Drone637/RoNGjHUzSTI/AAAAAAAAACU/ZyHRpiBn8Eo/s288/CIMG1265.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Make sure that you don't hit any electrical on the inside of your fender.</p><p></p><p><img src="http://lh4.google.com/Drone637/RoNGjXUzSUI/AAAAAAAAACc/SjdFNONZU_o/s288/CIMG1266.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Once you make your initial top cut, take out the sheet metal between the top and the bottom of the fender line.</p><p></p><p><img src="http://lh5.google.com/Drone637/RoNGjnUzSVI/AAAAAAAAACk/WwmsjXdktyw/s288/CIMG1268.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Here we decided to keep the original headlights. Another method would be to head straight to the left and put in rectangle headlights. Late 90's Chevy full sized rigs would be just about perfect. So draw a line on where you want to make the next cut.</p><p></p><p><img src="http://lh4.google.com/Drone637/RoNJdXUzSWI/AAAAAAAAACs/Y-19GzSkBWQ/s288/CIMG1271.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Sawzall!</p><p></p><p><img src="http://lh6.google.com/Drone637/RoNJd3UzSXI/AAAAAAAAAC0/D4vT10aBr0o/s288/CIMG1273.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Weld up the back side of the fender that you cut out.</p><p></p><p><img src="http://lh3.google.com/Drone637/RoNJeHUzSYI/AAAAAAAAAC8/EhmNkEjzssI/s288/CIMG1277.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Push the front of the fender together and weld it in place.</p><p></p><p><img src="http://lh4.google.com/Drone637/RoNJeXUzSZI/AAAAAAAAADE/_IrxvJMg8KE/s288/CIMG1280.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>You should have a gap under your fender, use a piece of scrap metal to fill this up. We used left overs from the fender on one side. It worked, but was a pain to weld. On the other side we just used some 1/8th we had laying around the garage.</p><p></p><p><img src="http://lh6.google.com/Drone637/RoNJe3UzSaI/AAAAAAAAADM/luRr7NESm1Y/s288/CIMG1283.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Next we built a guard for the headlight to replace the part we took out of the fender and welded it in.</p><p></p><p><img src="http://lh3.google.com/Drone637/RoNKLHUzSbI/AAAAAAAAADU/02FKhubO6Lw/s288/CIMG1284.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Clean up your welds.</p><p></p><p><img src="http://lh4.google.com/Drone637/RoNKLXUzScI/AAAAAAAAADc/ApXRMQFzQaQ/s288/CIMG1286.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Throw some paint on it.</p><p></p><p><img src="http://lh6.google.com/Drone637/RoNKL3UzSdI/AAAAAAAAADk/SHLqhbHPMgE/s288/CIMG1296.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Put the lights back in and your done. <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite1" alt=":)" title="Smile :)" loading="lazy" data-shortname=":)" /></p><p></p><p><img src="http://lh3.google.com/Drone637/RoNKMHUzSeI/AAAAAAAAADs/Pib3pAd4eWo/s288/CIMG1300.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p><img src="http://lh5.google.com/Drone637/RoNKMnUzSfI/AAAAAAAAAD0/AzxKHAZPZ_4/s288/CIMG1301.JPG" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>There are larger pictures online at <a href="http://picasaweb.google.com/Drone637/SJ410Fenders" target="_blank">http://picasaweb.google.com/Drone637/SJ410Fenders</a></p><p></p><p>I'll throw some pictures up after the test run on Saturday and see how it works.</p></blockquote><p></p>
[QUOTE="Drone637, post: 943977, member: 16725"] Just thought I would throw together what we have hacking on in the shop the last few days. :) The problem: The tires were rubbing the fender way to much once my springs broke themselves in a bit. Original Solution: Actually put bump stops back on the SJ. Solution we went with: Getting rid of a decent chunk of the fender. :D We wanted to keep a somewhat stock look with the full fender, so we went a slightly different route then most flat fender style conversions. First, take on Suzuki SJ [img]http://lh5.google.com/Drone637/RoNGinUzSSI/AAAAAAAAACM/eVS25EUgY0g/s288/CIMG1263.JPG[/img] Draw a line about where you want the new fender line to be. [img]http://lh3.google.com/Drone637/RoNLXHUzShI/AAAAAAAAAEE/GJbYQ1aPw8Q/s288/CIMG1264.JPG[/img] Ignore that line and just cut wherever you think looks good. [img]http://lh3.google.com/Drone637/RoNGjHUzSTI/AAAAAAAAACU/ZyHRpiBn8Eo/s288/CIMG1265.JPG[/img] Make sure that you don't hit any electrical on the inside of your fender. [img]http://lh4.google.com/Drone637/RoNGjXUzSUI/AAAAAAAAACc/SjdFNONZU_o/s288/CIMG1266.JPG[/img] Once you make your initial top cut, take out the sheet metal between the top and the bottom of the fender line. [img]http://lh5.google.com/Drone637/RoNGjnUzSVI/AAAAAAAAACk/WwmsjXdktyw/s288/CIMG1268.JPG[/img] Here we decided to keep the original headlights. Another method would be to head straight to the left and put in rectangle headlights. Late 90's Chevy full sized rigs would be just about perfect. So draw a line on where you want to make the next cut. [img]http://lh4.google.com/Drone637/RoNJdXUzSWI/AAAAAAAAACs/Y-19GzSkBWQ/s288/CIMG1271.JPG[/img] Sawzall! [img]http://lh6.google.com/Drone637/RoNJd3UzSXI/AAAAAAAAAC0/D4vT10aBr0o/s288/CIMG1273.JPG[/img] Weld up the back side of the fender that you cut out. [img]http://lh3.google.com/Drone637/RoNJeHUzSYI/AAAAAAAAAC8/EhmNkEjzssI/s288/CIMG1277.JPG[/img] Push the front of the fender together and weld it in place. [img]http://lh4.google.com/Drone637/RoNJeXUzSZI/AAAAAAAAADE/_IrxvJMg8KE/s288/CIMG1280.JPG[/img] You should have a gap under your fender, use a piece of scrap metal to fill this up. We used left overs from the fender on one side. It worked, but was a pain to weld. On the other side we just used some 1/8th we had laying around the garage. [img]http://lh6.google.com/Drone637/RoNJe3UzSaI/AAAAAAAAADM/luRr7NESm1Y/s288/CIMG1283.JPG[/img] Next we built a guard for the headlight to replace the part we took out of the fender and welded it in. [img]http://lh3.google.com/Drone637/RoNKLHUzSbI/AAAAAAAAADU/02FKhubO6Lw/s288/CIMG1284.JPG[/img] Clean up your welds. [img]http://lh4.google.com/Drone637/RoNKLXUzScI/AAAAAAAAADc/ApXRMQFzQaQ/s288/CIMG1286.JPG[/img] Throw some paint on it. [img]http://lh6.google.com/Drone637/RoNKL3UzSdI/AAAAAAAAADk/SHLqhbHPMgE/s288/CIMG1296.JPG[/img] Put the lights back in and your done. :) [img]http://lh3.google.com/Drone637/RoNKMHUzSeI/AAAAAAAAADs/Pib3pAd4eWo/s288/CIMG1300.JPG[/img] [img]http://lh5.google.com/Drone637/RoNKMnUzSfI/AAAAAAAAAD0/AzxKHAZPZ_4/s288/CIMG1301.JPG[/img] There are larger pictures online at [url]http://picasaweb.google.com/Drone637/SJ410Fenders[/url] I'll throw some pictures up after the test run on Saturday and see how it works. [/QUOTE]
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