Outer Limits 4x4 Board

So I am cutting the guards on the lux. What I want to know is, whats the best way to fold over a lip on the guard (ie to keep it structural and to also have something for the rubber flares to screw into).

Do I just hammer it over bit by bit or is there another way?

If you really don't need a lip, TJM make a rubber flare kit that screws in from the side instead of underneath.

The lip also gives some level of support to the guard that a straight edge wont provide, hence I want it. Plus I already have the flares as I am using them on the truck now, and would like to just use them again.

What I did was trace out where you want to cut, cut out with air hacksaw, then weld a strip of 2mm sheetmetal (preferrably with safety edge) horizintally right around the edge so that it sticks out 30mm.

Then attach plastic garden edging with screws, bondage style. What you get is something stiff as or stiffer than uncut guard, and sooo easy to adjust flare width.

I had to go this way cos my wheels stick out so far and I was worried about the whole "flares must deflect pedestrian on impact" thing.

Pretty cheap- I paid someone to weld the strip on for me too- but needs filling and painting to get 100 % bling.

Josh.

Tell me how to post pics and I'll put a couple up.

I have an account with photobucket and have loaded the images on- where do I go from there?

There is also a tool you can buy that will help to fold the edges over.

Imagine a pair of square nosed pliers but with a very wide nose........basically like a hammer head shark.........that allows you to slowly bend about 1.5-2 inches at a time..........but u only go part bends at a time, not the whole way.........although that will become fairly obvious once u start.

U will need to have that lip for strength reasons.

slosh wrote:Tell me how to post pics and I'll put a couple up.

I have an account with photobucket and have loaded the images on- where do I go from there?

right click the image. then properties... then you'll see the address of the photo under http://www.yourphotoaddresshere.html

then put it in here via [img]yourphotoaddresshere.html[/img]

Cheers

TOM

Thanks Tom.

On the Gen2 lux's there is a line on the guards about 1cm in. I cut along this line with a jigsaw and the bent another cm or so back with wide pliers and a mallet. I have yet to put flares on to finish it off.

I got the idea off Ruff he did the same thing. There is a post some on here about it. But the pics would be gone by now.

Top Cat wrote:There is also a tool you can buy that will help to fold the edges over.

Imagine a pair of square nosed pliers but with a very wide nose........basically like a hammer head shark.........that allows you to slowly bend about 1.5-2 inches at a time..........but u only go part bends at a time, not the whole way.........although that will become fairly obvious once u start.

U will need to have that lip for strength reasons.

This would work best IMO. Then tidy it up with a hammer & dolly. You can get a cheap panel beating set (includes dolly, no not the clone sheep) for under $20.

When I did mine is I cut with a jigsaw and metal blade then folded over the lip with a pair of pliers. It was too easy . Finished it off with a bit of paint along the edge where the paint cracked and then screwed on lawn edging.
When folding the lip do it a little bit of the angle at a time dont go right for 90 degrees in one bend. bend it to like 45 right along the guard then go back and finish it off to 90. It allows the steel to stretch as you go.
Paul.

My mate just cut his the other day...

A mixture of angle grinder and a jigsaw with a metal blade.

He drew 2 lines, at about 2cm apar the whole way, and cut the guard on the bottom one, and scored the top one so that it made it easier to happer and fold the lip back with pliers. This seemed to work well.

When i replace my guards, i will use this method.


Dave.

I used a hacksaw which worked fine because u can go very slow but I was to lazy to fold a lip
I used some black rubber edge from a boat shop to cover the sharp edge

i have done it shite loads of times all different ways. use a jig saw with steel cutting blades at a hacksaw like pace - fairly slow. make sure you flex your vehicle first and before you roll your lip you will need to make adjustments as it is nothing like what you think. get a piece of steel 12x25 0r bigger about 6 inches long. cut a slot about the depth of the lip roll at the end using the jig saw (or 2 blades in a hacksaw) file the entry to the slot to take the sharp edges off.

start bending thje lip by putting the lip into the slot to full depth and bend about 1/4 of the way and move over an inch and do the same. work towards the other side till complete. start at the beginning and bend in between where you were last time and so on. you will need to go over it four or so times. be gentle and it will look factory.

i then went an extra step and welded 50x3 on the lip to bolt convayer belt on to.

cheers bru

ToNkA wrote:So I am cutting the guards on the lux. What I want to know is, whats the best way to fold over a lip on the guard (ie to keep it structural and to also have something for the rubber flares to screw into).

Do I just hammer it over bit by bit or is there another way?

Dont worry about it just burn it I was told the best way to do it is to just slowly hammer the edges overto where you want them as cutting and folding the lip gives you a rough finish where you cut it.....i think that made sence

When I asked about this one a while ago I was told yet another way to do it...

BTW - Slosh, looks good too. That method is pretty good i reckon. Where did you get your flare material from?


Mark your line out where you want your guard to finish and then drill smalls holes along the line, about 1.5 - 2cms apart. Then cut upto those wholes and fold from there. I was told that this is good way as with body flex and so on, the end of the cuts can tend to tear further than you want.

The drilled wholes are apparently a little stronger. Sounds like it would work when you think about it.

If you are then wanting a flat lip, to then bolt flares onto it might be a good idea to fold every second cut section, then go back and do the rest. On the corners it may want to fold on top of the other pieces, unless you get fancy and add two cuts per whole so that the edges meet nicely.

Good luck with it, and show photos and details once done hey...

hely Meldge, have you cut your flares on the middy?

got any pics???





Bluey

Bluey wrote:hely Meldge, have you cut your flares on the middy?

got any pics???

Bluey

Nah, I haven't yet. Was talking about it a while ago, but wanted to see how the 35's went first. I get them this weekend but not sure if i will get out wheeling, hope i do on Sunday to Ormeau, if it is still open...

If they scrape, then I will be giving it a go... I like sloshs flares, but I don't wanna pay anyone for a similar job that i might be able to do myself...