I have been planning on building some tube fenders for a couple of months now. Since I finished working on my cage, I needed a new project. So this weekend, I finally got started...

It actually started back in February with the completion of my tube bender. I got some plans from a website and used some 2x2 square tubing I had purchased a couple of years ago. The finished product: It has a 1.5 die.


Now on to the fenders. I will be following a design that kegger1454 from the rubiconownersforum.com came up with. This is a picture of his completed work:


I took a 10 foot piece of 1.5" round tube and bent each end 90 degrees:


I cut them to them up into two pieces and used the extra to make the bottom tubes (the piece that will connect the top tube to the side bracket). The bottom tubes have a 55 or 60 degree bend.




My plan was to cut up my fenders to fit the tube fenders over them. I had ever marked the cut lines.



After thinking about it a little, I decided that I did not want to cut into such nice looking fenders. I just couldn't do it. So I started to look for some used fenders to cut up. After looking at what people were asking for used fenders, I decided just to remove the fenders and build my own inner fenders.

I built the rear and front bracket with some 3/16 thick 2" wide steel plate.


I then tack-welded the top tube to both brackets. Before tack welding I made sure it was level with the measurements I had taken from the stock fender.


I then tack-welded the bottom tube.


I then started to plan on how to build my inner fenders. After some research and looking at some complete replacement tube fenders. It started to look like it was going to take a little more effort than I thought.

I was looking at the driver side fender that I had on the floor thinking about how I was going to build my inner fender when a crazy idea popped into my head. What if I cut the fender on the inside, separating the inner fender and the outer fender. That way I can build my tube fender and keep the inner fender. I notice that they used 3 bolts in the front and 4 bolts in the rear to attach the inner fender. So it should be sturdy enough on its own.

Since I had my grinder with a cutting wheel handy, I went right to work on separating the fenders. Here is the aftermath:

Stock outer fender:


Stock inner fender installed on the jeep:
[img]http://i184.photobucket.com/albums/x135/rubicon4x4/Jeep_Fenders/j-fender002--1.jpg[/img]

My next step is to add some 1/8 plate to the tube fender and completely weld the tubes. I will also be adding some of that plastic molding that is used on the doors to the inner fender. I figure it will help with the metal to metal rattling or rubbing.

Since my jeep is still used as a DD, I use 33" AT tires to drive on. When I hit the trails I swap in my 35" MT tires. With that in mind, my thought was that the fenders could also be swapped, from tube to stock. We'll see how that works out.

Got a little done yesterday.

Cut out the top fender plate from a 10"x43" piece of 1/8" steel plate:

As you can see from the marks on the steel plate, I should be able to get both side from this one piece.

Used a reciprocating saw and cutting wheel to complete the cutout.


Tube fender frame:


Installed on the jeep for fitment. A little trimming is needed but not much:


With the hood closed:


At this point, its all tack-welded. I need to spend some time welding it all together properly.

After making sure the tube fender fit correctly, I removed the tube fender from the jeep and tried to see how the stock fender would fit. Its actually very easy to swap from one to the other. Very little effort involved.

Stock outer fender installed.

Good little write up. I think I will be using this thread when I make tube fenders for my CJ5. <img src="/forums/images/graemlins/cheers.gif" alt="" />

Wednesday:
I completed the welding of driver side tube fender. I adjusted the top plate and welded it in place. I also cut out the passenger side top plate.

Once both tube fenders are complete, I will start to work on a 3" fender flair.

Thursday:
Yesterday I took a piece of 20 x 17 steel plate and traced the two bottom pieces:


I cut out one of the pieces and trim it to fit:


I also cut out the passenger side fenders. I already had removed the airbox in a prior mod so the only thing to remove was the fuse/relay box. I cut the fender with it still installed on the jeep. I should be able to remove the rear and front screws and remove the outer fender with very little effort.


Today is my daughters birthday so not much work will get done. On Saturday I should finish the passenger side.

Very Nice! What's your plan for turn signals?

I was thinking of putting on some JK lights on the grill, like this:

Got a little work done this weekend.

Started off with a little bending secession:


And ended with this: 3" flair


I ran out of argon\co2 mix so I need to get another tank.

I just ordered 2 of these:


Paid 28.00 each with free shipping from JPartsOnline
http://www.jpartsonline.com/catalog/?N=10852+4294964668+1557+9323

You've got some top notch stuff going there. Keep up the good work and the great pics! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Thanks,

I just need to put in a brace in the front of the fender and clean it up a little bit and the driver side will be ready.

Hopefully I can get started on the driver side fender today. I need to trim the tubes and tack them in place. I will post some pics tomorrow of the progress.