korda's XJ
korda | jeep | mods | TJ flares (front)
Installing TJ Flares on a 92 XJ Front Install | Rear Install

Tools:

  • Jigsaw w/Metal Cutting Blades
  • Sawz-All
  • BFH
  • Drill with various bits
  • Sockets and Wrenches
  • Welder
Hardware:
  • 40-50 1/4” Bolts, 3/4” Long
  • 100 1/4” Washers (I’d recommend Fender Washers)
  • 5 cans “Great Stuff” Expanding Foam
  • 2 Tubes of silicone
  • 2 cans Rubberized spray on fender liner
  • Wide Masking Tape
Front
The reason I decided to install TJ flares on my XJ was to open up the wheel wells in order to fit larger tires without adding lift. This makes the Jeep more stable by keeping the center of gravity lower than if I was to lift. It was also a cheaper alternative to more lift. On an XJ cutting the fenders eventually becomes a necessity in order to fit larger tire without rubbing. The TJ flares also provide more coverage to the outside of the body. This is needed because of the larger and wider tires.

This project started with a trip to the liquor store to get a case a beer for friends that lent a hand. One friend in particular is Dan. He lent his garage, welder and skills to the project.

The first step was to remove all the fender flares. Removing them was easy because every bolt but one snapped off in the process. The flares are held on with plates that have bolts passing through them and then through the fender where a bolt holds it on. I also removed the rubber liner for the front fenders. These are just held on with trim fasteners and a few tugs got them out. Removing the air damn in the front was a small pain. It’s bolted on with 7mm bolts and fender washers up behind the bumper; I had to fit my hands up there with a 1/4” drive socket to get them out. Having smaller “peter beaters” would have been helpful.

After removing all the fender flares I could see that my fenders had begun to rot away. Most of this rust would get cut off when I trimmed the fenders so I wasn't that worried about it. Having lived in the Northeast this is to be expected from a 10-year-old vehicle.

I also needed to pop out a dent in the front passenger fender before I started. This dent was a result of the tire traveling up and back and crushing the fender in. More room for the tires was definitely in order.
Next, I put tape over the area to cut so that I could trace the bottom of the flare onto my fender. The tape also provides protection for the paint when cutting. After the area was taped up I traced along the bottom of the flare after positioning it where I wanted.

The next step separates the men from the boys. I had a beer and readied the jigsaw. After saying a prayer to the Jeep Gods I laced into the fender. I cut along the inside of the line I drew. Remember, you can always cut more off but you can’t put what you cut back on. The cutting was the easiest part of the install. The jigsaw made short work of the metal and I was left with a large opening, at least 3” larger than stock all around. I also cut the front of the fender about one inch lower than the turn signal light and folded the metal up flush with the bottom of the light. This provides a lot more room up front and is the way 97+ XJ’s come from the factory.

The next part of the install was to make it look nice. After folding the front part of the fender up I cut the lower front support brace out, this is the last thing that needs to be removed in order to provide a wide-open area in front of the tires.

There is a standing seam on the inside of the fender that I beat flat with a hammer. If you’ve got any pent up frustration here’s your chance to get it out. It took more beating than I expected to get it flat but I didn’t want that seam coming in contact with my tires.
To bolt the flare up I held it up to the fender and marked the top two holes. The positioning was made easier because I left the lip on the bottom. After marking the top twoholes I drilled holes and bolted the flare up. The last modification that needed to be done to the flare was to cut it to fit around the trim on the Cherokee. I used trial and error, holding it up marking and cutting with a sharp utility knife. After this was done I marked the rest of the holes on the fender and drilled them. I bolted the flare up to make sure it fit and removed it one last time so I could paint the bare metal and try to ward off the rust. When the paint dried I bolted the flare up and put the light in. I tapped the light into the side marker light in the front.
Since the rubber liner was removed the inside of the fender needs to be addressed because mud and road debris will fling back onto the inside of the door hinges because the fender is open all the way through. My solution was to make a barrier with expanding foam and then shape it with a knife and finish with spray on rubberized fender liner.

Rear Install