Project Bushwacker Fender Cut Outs

**Dads_taxi** · 11-12-2007, 05:24 PM

This project allows room for bigger tires and provides coverage to prevent rock chips. Recognizing that Bushwacker DOES NOT make cut out flares for the Titan, this project uses cut out flares for Chevy (part numbers 40009 and 40010).

This project took about 3 weeks from start to finish. I have no auto body experience, just a creative mind and patience.

1. Getting Started: It all began with prepping the flares to remove the tabs and to adjust the contour just a little to fit the Titan. This was mainly accomplished from some gentle heat from a propane torch. The front flares had a lip removed. The holes for all the screws were pre-drilled.

2. Trimming: Since there are no templates for this project, marking the fenders was based on visual appearance. The fenders were trimmed in stages, not as to cut too much. (Unlike hair, it won’t grow back if too much is removed.) A sawsall worked great on the tough cuts, but a good set of tin snips did most of the deed. The fenders were actually trimmed more than what these pictures show. Some extra metal was trimmed on the day the flares were installed. Since the body of the flare is big, there was a lot of latitude for cutting. Enamel primer was brushed on to all trimmed surfaces.

3. Fuel Door: The major hurdle was the fuel door. Trimming the flare was out of the question. There were only 2 real options: (a) The gas filler could either be brought through the wheel well and the door permanently covered or (b) Trim the fuel door to fit around the contour of the flare. I chose to trim the door, so I went to my local body shop for help. They did a nice job and the door works great!

4. The Rear: Much of the inner fender lining had to be removed as seen in the pics. The rear had a lot of metal removed. Most of the fender braces were removed as well. The braces toward the rear were remounted in new locations for support. The flare itself added strength to the rear fenders. After all the trimming was done, the flares were installed from the bottom up in order to prevent any gaps. After the installation was complete, the body shop had filled in the minor portions along the bottom sides with filler.

5. The Front: They were easier to install. The key was to make sure they were level. The pinch weld mod was done about a year ago, which made this task easier. THE PINCH WELD MOD IS REQUIRED to make this work. In fact, a little more trimming is needed along the bottom edge. As you can see, a milk jug can fit in there. Those tires are 37’s! So 40’s will be easy to get in there regardless of wheel back space. The only problem is that my wife had bought the 37’s for me. Say no more.

6. Fender Lining: KYDEX plastic was obtained from interstateplastics.com. It was trimmed to 12” strips placed behind the flare in all fender wells. In the rear, much of the old lining was removed. The extra lining was attached to the flare, then to the original lining. In the front, the old lining was not removed. It was just slitted and pushed back toward the firewall. The layer of new lining covered everything nicely.

7. Mud Flap Disclaimer: The current mud flaps are a little junky, but only there temporary to keep Johnny Law happy until I get a much better flap setup.

More pics to follow...

**Dads_taxi** · 11-12-2007, 05:29 PM

Here are some more...

**Dads_taxi** · 11-12-2007, 05:33 PM

and more pics...

Sammy Sandbag · 11-12-2007, 05:50 PM

You are one brave soul. Looks like it turn out well, surprisingly (considering they are for an entirely different truck.) Look like you have more than enough room, any thoughts of going with a larger tire?

Rhino404 · 11-12-2007, 05:55 PM

Quote:

Originally Posted by Sammy Sandbag

You are one brave soul. Looks like it turn out well, surprisingly (considering they are for an entirely different truck.) Look like you have more than enough room, any thoughts of going with a larger tire?

I'm w/ Sammy...you need at least 13.5" wide tires to fill in some of the additional room you've created.

Sammy Sandbag · 11-12-2007, 05:58 PM

Looks like I skipped over this:

Quote:

As you can see, a milk jug can fit in there. Those tires are 37’s! So 40’s will be easy to get in there regardless of wheel back space. The only problem is that my wife had bought the 37’s for me. Say no more.

Just swap em out, if she asks just tell her you put more air in the 37's.

**Dads_taxi** · 11-12-2007, 07:16 PM

I would like to get 40's, but I'll have to wait. But I'm hoping some teenager will come by tonight and slash all 4. That could speed up the tire upgrade.

BECHLYF · 11-12-2007, 07:44 PM

Quote:

Originally Posted by Dads_taxi

I would like to get 40's, but I'll have to wait. But I'm hoping some teenager will come by tonight and slash all 4. That could speed up the tire upgrade.

I think it looks silly. You definitely need bigger tires. and when you do, where you gonna get gears? I don't think anyone has swapped gears on the front. 40's + NO gears = ONE SLOW SLED OR GUTLESS WONDER.

HEY! this is NOT suspension shouldn't this be in Parts and Accessories.

**Dads_taxi** · 11-12-2007, 09:59 PM

Quote:

Originally Posted by BECHLYF

I think it looks silly. You definitely need bigger tires. and when you do, where you gonna get gears? I don't think anyone has swapped gears on the front. 40's + NO gears = ONE SLOW SLED OR GUTLESS WONDER.

HEY! this is NOT suspension shouldn't this be in Parts and Accessories.

I chose this forum since there are some who want to get bigger tires under their rigs and they're usually looking here for ideas.

Your opinion is noted.

lowlypawn · 11-12-2007, 10:06 PM

Pretty cool, I don’t think I would be brave enough to start hacking my fenders.

Hey what kind of air suspension is that? It doesn’t sit directly over the axle?

**Dads_taxi** · 11-12-2007, 10:21 PM

Quote:

Originally Posted by lowlypawn

Pretty cool, I don’t think I would be brave enough to start hacking my fenders.

Hey what kind of air suspension is that? It doesn’t sit directly over the axle?

That is a Air Lift air bag - http://www.airliftcompany.com/ . It increases your load capacity. It is not used for lift, but to keep the truck from squatting when towing or carrying a load. PRG sells them. He will get you a great deal.

54warrior · 02-04-2008, 10:43 AM

This photo killed it for me, looks goofy only coming partways down the bumper end...... nice job otherwise, you're the only one that has to be happy with it. And I give you credit for having the cahones to hack the sheet metal. OUCH!!! That had to bring tears to your eyes doing that!!

**DeadRiver** · 02-04-2008, 11:34 AM

i wondering what would have happened if you bought new quaters from glassworks or another aftermarket company??

+1 for having the balls to cut up your truck!

MIZZARK · 02-05-2008, 12:31 AM

Quote:

Originally Posted by DeadRiver

i wondering what would have happened if you bought new quaters from glassworks or another aftermarket company??

+1 for having the balls to cut up your truck!

^^im with him.. make that +2

**DeadRiver** · 02-05-2008, 08:20 AM

Quote:

Originally Posted by MIZZARK

^^im with him.. make that +2

......probably cost.