Outer Limits 4x4 Board

OK, I started doing some work on my front guards today. I wasn't quiet happy with where the TJ flares were sitting so I adjusted that and cut out some excess on the inside of the flare. Then I traced the inner outline of the flare onto the guard and added about 10mm for a lip. It came out like so (note the hatched portion which is gettin' chopped ):

I decided to take the wheel off because I knew i'd have to get in under the guard later on. Then out came Mr. Grinder and sparks flew. A few minutes later I was left with this

I had allowed about 10mm for a lip to be folded back in to give me a bit more metal to weld to, the photo is some of it folded under. Now this was not the prettiest job ever, and I should have used a dolly set to make things easier not to mention make the job a bit prettier. I did see a set at Super Cheap but decided to keep my $18 and go the pliers. My bling flares will cover these sins so

Here is a shot of the lip from the inside of the guard. I've got this bit clamped up with vice grips but for some parts I couldn't get the vice grips in there so I had to hold it with one hand and tack it up. Not very easy especially when I was having trouble getting the right settings on the MIG Although in hindsight I think I should have cleaned up the sufaces I was welding

Here is a shot after I had most of it bent and tacked up. At the front I want it to follow what I have cut out but that means going from the round guard (stock zook) to the squared out shape of the jeep flare. It was at this point where I stopped and scratched my head for a while. I was also thinking about bringing the front of the guard forward while I was chopping things.

So currently I am at the stage where I am trying to figure out the best way to do the front of the guard. My question (and this is directed to the Vic guys that seem the most familiar with this mod) is where have you guys taken the guard forward to? How much of the headlight bucket have you chopped out? If anyone has some close up pics of how they've done this it'd be nice. My thoughts were to brace the inside of the headlight bucket then chop the bottom off it and bring the wheel well all the way to front of the little flat bit underneath the headlight. Basically, i'd be making the opening as large as possible. Here is a pic of my headlight bucket at the moment, feel free to add suggestions & photochops etc.

This is where I cut

bigsteve wrote:This is where I cut

Thanks Steve. Did you end up bracing the headlight bucket?

im thinking lj front inner guards damo...

mud4b wrote:im thinking lj front inner guards damo...

Dunno what the LJ ones look like. Got a pic?

sent e-mail dude..

Here is the pic Mud4b sent me

If you got some of those, you could merge the inner guard and them baffle off behing the headlight to protect it from crap.

Mudzuki wrote:If you got some of those, you could merge the inner guard and them baffle off behing the headlight to protect it from crap.

Too much stuffing around I think. Though I do like how those LJ guards look. What I think I will do is chop out front part of the guard and fill it in with sheet metal similar to that LJ guard. I'll be trying to make the opening as big as possible.

33s should fit no worries. I might even sneak a 35 in there

Damo wrote:

bigsteve wrote:This is where I cut

Thanks Steve. Did you end up bracing the headlight bucket?

Nah I just let the lugs on the swampers do the clearing