Here's my question:

I have a '97 4.0 sport ... 270,000 kms (approx 170,000 miles).  engine has about 140,000 kms.  tranny was rebuilt around 150,000 kms (ouch).

I've replaced the fuel pump, starter, shocks, sway bar links, pinion seal, spider gears, ujoints, rad, rad, etc.

'new to me' engine came with all accessories except starter.  turfed the A/C.

I've kept it oil spray'd.  took the front end apart when i installed the replacement engine and eliminated all rust that i could find.  did the same in the rear when i replaced the fuel pump ... since i had to drop the tank, and drop $500 on a new fuel pump.

Here's what's bugging me ... the TJ's are prone to rust coming up through the front fenders, right above the tire.  the drivers side fender is really starting to get ugly.  i can't weld, though i'd love an aftermarket tube fender kit.  I've had the fenders off, so replacing them should be easy.  should i look for used ones, or is there something aftermarket out there that is 'bolt in'?

My jeep owe's me nothing, and i ain't making payments.  I just know that if i dig into the fender with a grinder, what's on the surface is nothing compared to the rot underneath.  oh, and the passenger side fender isn't too far behind.

any suggestions welcome, just needs to be quick enough that it's done by the time my wife get's home.

Pete

Id say, sand them down and seal them, then paint them as a temporary fix till you can get some new tube style fenders. Unless you can afford some now, then get some tube style fenders if ya like them. if the wife isnt for getting new fenders, just cuz of a little rust, take it out wheeling and "damage" the  stockers to make a good case for getting some new fenders. but dont damage it so bad that it ruins any other part of your jeep. Thats how i would do it, seems to work for me when i used to have to convince my mom to let me do some thing to my Jeep.  

Problem is, the rust has come up from under the fender.  it's toast.

i could pull the flares off, cut the fronts to eliminate the rust (i think we're ok with no fender coverage in ontario). and clearance the rears to fit 33's with no lift.

wifey would probably be ok with that, since it would only raise the jeep 1.5"

we still rely on it as a second vehicle, but i think it would look stupid without some kind of front fender.  

any thoughts?

btw, i would run 33x9.5.  they'd tuck in nice and work ok in the snow/ice.

Edited 4/2/2006 10:31 pm ET by PeteBarton

Yea i would go with the tube style fenders...the flattie style that you can get from like posin syder customs. If possible, maybe a spacer lift would be the way to go also. Keep the fenders as no fenders would look wierd. Look up the laws around there also and see what you need. Im sure the local police would be willing to give you the written laws and tell ya in laymans terms what it means. I know with Washington State here, we dont need fenders if its a nice day (yea right) or if we have Mud flaps to cover the rear wheel from rearward spray. So just check out the local laws and see what you want, then talk it over with the wife (always want her approval...or bribe her some how) and then get what you want/agree on.  

The Poison Spyder tube fenders utilize your stock inner fender (keeps under-hood changes to a minimum) and a portion of the top of the fender. Go here to see what is reused:
http://www.spydercustoms.com/index2.php

Click tube fenders and then scroll down to the instructions. If your fenders are too rusty in these areas you may need someone else's tube fenders.
Try http://www.rev1crawlers.com/ or Smittybilt.

now that's just what i was looking for.  i assumed there would be welding required, but from what i see, i can cut out all the rust, bolt on the new fenders, done.

Thanks!

Pete

Yea thats one of the great things about the aftermarket, they take all the work outta adding those fenders to your TJ. Just wish some one would make some cool fenders for my ZJ. Im stuck to making my own. Glad your gettin rid of that rust before it spreads to the rest of the TJ. I know how hard rust can be to deal with. Im dealing with it on my ZJ.  

i need to confirm my local laws, but i have been somewhat encouraged to just cut the offending metal and live with no fenders.

assuming that the local police ok it, how far do i cut in ... while keeping the option to put tube fenders on?  inner fenders are fine.  rust is at least 1" from where the hood meets the fender.

I'd definately have to do something with the dorky front bumper.  ends are long gone, but i'm thinking that i should cut it at the frame.

rear flares will have to be tossed ... but with this many miles on it, i think it's time to get ugly and functional (or disfunctional).

sawzall here i come.  

even wifey know's it's a better option than letting the cancer spread.

well i know that with the tube style fenders, you need to cut some of the innerfender off... so i would say pull the fender off and then figure out how much of the inner fender needs to be cut, or cut till the rust is gone, and then if needed when ya buy the tube fenders add some metal back to them. If you can get away with it, just yank the fenders off all together...front and rear. I know a couple guys around here with trucks that have yanked the beds and all they run are some mudflaps in the back. so you might just need some mud flaps in the rear to stop rearward spray. If your daring, you could run with out any of that stuff and wait till the police stop you and then hope they give ya a fix it ticket or ya can play the excuse you were 4x4in and smashed the fenders and had to remove them in order to drive the jeep.  If it was me, i would buy the tube fenders and then see how much of the inner fender needed to be cut off. If there was rust still around, see if ya can find a wrecked one with some decent inner fenders and then cut those down to fit the tube fenders. Lots of options you have, and sounds like the wife is on your side. Make sure to check and recheck all your stuff before you cut, as its easier to do it once right, rather then 5 times wrong. I might only be 23, but ive learned that the hard way...  

yes sir.  good point.

going to take a step back, figure out what's legal.

if i can run with no front fenders ... darn it, i'm going to.  

worst that can happen ... i buy new fenders.

anyone have a pic of a TJ with no fenders?  not one of the heavy mod's ... just something that will give me an idea of what mine will look like when i cut out all the rust.

31-33's

thanks, Pete

Do your inner fenders not unbolt?? if they do, just take off the outer fender and then  the inner fender and see what it looks like then, as that would be the most extream it would look. and yeppers, worst that can happen is that you need to buy some new ones. Wifes given her approval any thing is better then the cancer. thats like a free ticket to a strip show. means you can do what you want and not get in trouble, as long as you can justify its some how better.

last time at the strip show ... wife bought me a lapdance (b-day).

it's all one piece.  gonna talk with the local enforcement before i decide.

life is good, and finally getting into mods would be awesome.

inspired by the no lift jeep with 35" tires.  i won't go that big, but even with the 31's ... i can have some fun.

will save pennies for 33's.  they will be dorky 9.5's.  that's what i want.

oh, and if there's anyone in eastern ontario that wants to upgrade to 8" alloy rims ... let me know.  brand new 31x10.5's AT's.

Pete

Edited 4/3/2006 9:25 pm ET by PeteBarton

Yea if i could run fender less on my ZJ i would but it looks like i got in a wreck and have no insurance and i know the cops would be all over me for that. I already run my fenders with as litta bolts as possible, in case i get into some trouble 4x4in and need to remove them. As for the tires, may be dorky but as long as you like it, thats all that matters.  

now here's a possible easy fix.

I'll buy flares for the new jk, and fit them.  then it'll look ok if i keep the rear flares.

duh!

Pete

Na...the new JK flares/fenders or what ever it is they call them, look like some thing off a liberty. Im sure it would be cheaper any way to go with the tube style fenders....or no fenders at all if ya can get away with it...