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  1. #1
    Driving his wife's Jeep Ringer's Avatar
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    01-19-2012
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    Chardon, OH
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    DIY Tube Fenders

    Ok, so this is all in my build tread as well, but figured I'd save people some time and put it all in one place.
    I am doing a 3" stretch on my two door, so buying tube fenders was not an option. I also am going for low COG, and wanted very high clearance. I settled on 1.25"x.120" wall DOM tubing for the fenders, 14 gauge steel for the tops, 3/16" plate for the front fender backing plates, and PSC corners for the rear.
    Fronts:
    I started by making a posterboard template, and then transfering to 3/16" plate. I used three pieces of plate, and welded together, rather than buying one big piece.

    I used a plasma cutter to cut the backing plates.

    The plates were then clamped to the body, and mounting holes drilled and nutserts installed.

    My old tubing bender took a crap on me at the beginning of the project, so here is what I picked up. A JD2 model 32 bender with a SWAG hydraulic adapter and a Larin Hydraulic jack. I build the stand for it.

    Time for some geometry to figure out the bend angles and tubing gain from bending.

    Bending up a front tube

    Front fender tacked into place. These are 1.5" narrower than factory.


    I added some support tubes and a plate with a stud to catch the factory support.

    Fronts all bent up.

    Skins were then cut from 14 ga steel, again using the plasma cutter. They were cut larger than needed, and then cut down to size once tack welded on.

    The front curve was compound, and took some heat from the torches and body hammers to shape into place. Skins were tacked into place from the inside, the outside was then ground smooth to the tube.

    The entire outer edge was welded, then ground smooth. I used a combination of flap wheels, a belt sander, and hand sanding to get them smooth.
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  2. #2
    Driving his wife's Jeep Ringer's Avatar
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    01-19-2012
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    Once finished, I sent them off to powdercoat for a texture black finish. I then ran a bead of black silicone on all inside edges to prevent any future rust.

    They were then mounted up using 5/16" 316SS fasteners.



    Also ran a Truck Lite LED for side marker lights.

    Rear write up coming...
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  3. #3
    Driving his wife's Jeep Ringer's Avatar
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    01-19-2012
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    Rear fenders...
    Rear were constructed the same way as the front, but were welded to the PSC rear corners. First the corners were mounted per PSC's instructions.
    A piece of 1/8" plate and some gussets were then welded to the front edge of the corners.

    The rear tubes were then bent and tack welded in place. These are also 1.5" narrower, but appear more so because they are welded to the outside of the body.


    Rears were then skinned in 14 ga using the same process as the front.

    Ground smooth.

    Test fitting.

    Back from powdercoat and installed.
    Last edited by Ringer; 03-25-2013 at 11:21 AM.
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  4. #4
    One Ton MoFo Heat Treater's Avatar
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    12-17-2011
    Location
    Mass
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    2,425
    Nice work... now if you could make about 20 pairs you'd make few people happy!!
    ridin 44's with mud on the doors
    Web Wheeler extraordinair
    The only way to make a Jeep do what you want is to cut that bitch.
    www.krawldaddyoffroad.com

  5. #5
    Senior JK Freak TheBlackSheep's Avatar
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    01-10-2012
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    Licking County, OH
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    2,299
    Epic! so quality.
    0||||0

  6. #6
    Senior JK Freak Mac's Avatar
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    02-08-2012
    Location
    Pickerington, OH
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    862
    Wow. That is some awesome work. Those look great

  7. #7
    Driving his wife's Jeep Ringer's Avatar
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    01-19-2012
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    All done..



    Last edited by Ringer; 03-25-2013 at 11:40 AM.
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  8. #8
    Driving his wife's Jeep Ringer's Avatar
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    01-19-2012
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    Chardon, OH
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    Thanks guys! Overall, they are a pain to make. Doing everything by hand I have about 40 hours of labor into them. The nice thing is that I only have $250 in them(not counting the PSC corners).
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  9. #9
    JK Freak DMadole's Avatar
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    11-12-2012
    Location
    San Diego, CA
    Posts
    146
    They look professionally done, great job.

  10. #10
    Freak For Life Jeepenjk's Avatar
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    02-14-2013
    Location
    Omaha, NE
    Posts
    271
    WOW! Man you did a f-ing awesome job they look great.
    The side marker light is very cool I like where you put it.
    2008 JKU Rubicon Modified Stock Front Bumper, Rigid Dually 2 LED's,
    TeraFlex 3" Full Flex Arms, Pro Comp Wheels, Falken WildPeak AT Tires, Bed lined Grill, Rugged Ridge Hood catches, PS Evap Skid.
    and more to come very soon!

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