Outer Limits 4x4 Board

I am about to order 2" wheel spacers for the HJ60 and I may need to cut the front gaurds to allow full up-travel without rubbing.

Cutting them is no problem, but whats some good ideas for folding the edge so I am not left with just a cut edge? I dont want to cut my tyres to shreds (if it still rubs a bit) and I think it would be safer too (especially for little kids who run their hands over everything...and when working on it).

I have searched IH8Mud and Pirate and have found a few good threads, but they dont really answer the questions I am asking.

The only ideas I have in regards to folding the edge is either...

1) Make small cuts into the gaurd (10mm) every couple of inches allowing the edge to fold easier...

2) Weld a length, 10-15mm wide onto the cut edge at 90 degree angle for the new lip...but this would involve alot more work than the first idea.

Any tips from you guys/girls would be great!

Afterall...I make tents for a living!

I've done a VW wagon to fit larger tyres by cutting slots in the existing guard, bending them out to the required position, then glassing a garden hose inside for the rolled edge. Something along these lines may work, tho I wouldn't like a coupla big tnucs tryin' to lift u out of a bog by the guards.

here is a few pics of how i cut and folded a lip on my GQ guards mate
first i folded the factory lip out so its flush with guard, then i marked where i wanted to cut and where i wanted the lip to be


then i cut away the excess metal and using tin snips i cut every 6 or so inches to allow it to fold in easier, then using small multi grips and a flat hammer i folded the lip over



and it ended up like this

There is no real reason to cut slits in a guard to fold a lip. Just work it very slow with a hammer and dolly or 2 hammers if you dont have a dolly, you will stretch the metal to shape with no effort at all. Start at one end and work your way to the other end slowly just folding it slightly with each hit and then work back to the start again. It can be a little time consuming but you should be able to do it without even hurting the paint as long as the paint is good quality. I have folded new lips on guards heaps of times on all different vehicles and have never had to cut slits to do this. And rarely had to touch up the paint when finished.

The biggest problem with cutting slits is at every cut you usually get a small fold or dint on the outside of the guard and its still no safer for kids to run their hands around as now you have a serated edge.

thanks for the replies guys...and the pics!

Good point on the seperated edge thing RUFF...didnt think of that obviously.

Also what are the pros and cons of removing the inner gaurd?

I would not remove the inner guard. You will blow the worlds supply of crap all over the motor, have nothing to mount anything to, but mostly, the front clip will loose nearly all of its strength. Cracks, vibrations, and really easy to damage panels normally result from ditching the inner guards.

Steve.

Go buy yourself a set of folding pliers from the hardware store and use the same method as ruff said.

Heaps easier thab using a hammer and only cost $45- for a set of Irwin ones that I am yet to break ( approx 3 years and for 2 of that they were used 6 days a week )

Nick

i just did this to the rear wheel arches of my 40 this afternoon..

outlined the cut area with marker, grinded the excess and then using pliers bent it back under to form a lip.. when it was over 45deg under i got the hammer to it and flattened it out.. sure it stuffed up the crappy paint just but it's getting a respray anyway.. the corners just needed a little more massaging with the hammer.. but it came out pretty good..

once the flares went back on you could hardly tell it had been chopped..

no pix of the process but heres some pix of the result.