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.     We wanted to keep a somewhat stock look with the full fender, so we went a slightly different route then most flat fender conversions.

First, take on Suzuki SJ



Draw a line about where you want the new fender line to be.



Ignore that line and just cut somewhat close to it.



Make sure that you don't hit any electrical on the inside of your fender.



Once you make your initial top cut, take out the sheet metal between the top and the bottom of the fender line.



Here we decided to keep the original headlights.  Another method would be to head straight to the left and put in square 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.



Sawzall!



Weld up the back side of the fender that you cut out.



Push the front of the fender together and weld it in place.



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 3/16th we had laying around the garage.



Next we built a guard for the headlight to replace the part we took out of the fender and welded it in.



Clean up your welds.



Throw some paint on it.



Put the lights back in and your done. 




There are larger pictures online at http://picasaweb.google.com/Drone637/SJ410Fenders

I'll throw some pictures up after the test run on Saturday and see how it works.

Two things come to mind.

Trimming the fenders never really did much for me. But now after looking at your pic's and thinking of the old 2A I used to have, that looks kind'a good. Sorta.

And the second is you need too either wash and spray bomb the whole thing or go rub off some of that new paint. That new mod stands out like a sore thumb.

it looks good but i think it looks like a jeep(a bit)

With the longer front springs we were rubbing the bottom pretty hard when turning into the fender.  That stopped it from being able to flex up about 4 inches.  This should help fix that problem.  We might still need to put a bump stop on it though.

The entire thing is going to get cleaned off and repainted later this summer.  But I have a Rim Rock trip planned in mid-July that comes first.  Then a Scout 800B that needs to be rewired. 

I figure one or two trips into the woods and the front end will look like the rest of the rig.  I used the same spray can after all. 

it looks good but i think it looks like a jeep(a bit)

Did you HAFTA use the "J" word???

Quote from: BigRedZuki on June 29, 2007, 10:13:46 AM

it looks good but i think it looks like a jeep(a bit)

Did you HAFTA use the "J" word???

I'm thinking the slotted grill threw him off.

 

Still waiting on pictures, but a quick pictures from at the end of Cable line up on Reiter.  The tires aren't rubbing yet. 

mostly the flat fenders, but when or if you put flares on it will look wicked. i meant no offense too buy the way. jeeps are over rated

I know they are over-rated.  That is why I sold my YJ and drive a Zuki!   

Flares will be coming eventually, I have some of the generic flares I've looked at putting on.  But I want to make sure that my tires are not going to rub when I bolt them on.

ya and its too bad that zukis are completely under-rated. better for us thought cause parts could become expensive when in high demand, but on the other hand there is not as much parts for us and therefore raising the price. but better under rated than over