Seeking advice on how to cut rear fender

[Eddie94]

At my disposal I have a Dremel, a hacksaw, a jigsaw and a circular saw. I don't have much experience slicing up body pieces, and I'm sure most of those options will work alright; I'm just throwing this out there to see if anyone knows an easy tip or two, like "do the circular saw, it'll cut through like butter" or "stay away from power saws, they'll chew it up, do it by hand". I'm planning on painting next week (rustoleum and rollers, thinking of writing it up), so no better time for cutting/filing/sanding than now. Thanks!

 

[Maniak]

We didn't do anything special when we cut that off on our X.

I just used a cordless sawzall and a 2nd pair of hands to keep the metal from flapping when we got near the end of the cut.

removing extra metal -2 by maniak_az, on Flickr

~Mark

 

[92exp4x4]

Your jig saw with a metal cutting blade will be your best option. I have a Dewalt grinder with cutting wheels that I use to cut sheet metal, but of what you listed that will work best.

 

[Bruces expo]

I Do Believe there is a brace behind the middle of that panel Above that rubber boot . I was Going to cut mine the same But thought about Re using My Stock flares for On Road Use .

 

[Eddie94]

While I would LOVE to own a cordless sawzall I was asking for the best option of my four available choices-- was leaning towards the jigsaw since I figured it was most like a sawzall

Thanks!

 

[Bruces expo]

While I would LOVE to own a cordless sawzall I was asking for the best option of my four available choices-- was leaning towards the jigsaw since I figured it was most like a sawzall

Thanks!

Well The Jigsaw sounds like your best option ! , Seeing as you can use the Jigsaw one handed and hold the panel with the other !. Good luck and post if Possible ! .

 

[Eddie94]

The fender got pushed and bent upwards in half due to an accident, plus I like the look without it, but cutting into it proved to be too much for old Mr. Craftsman Jigsaw

Broke some teeth off and it headed to the big toolbox in the sky. Maybe it's time to go Sawzall shopping...

 

[92exp4x4]

Poor thing, they just don't build them like they used too. The one I use, my dad bought new in the early 80s. Its been a useful tool in many of his and my projects since.

Oh well, its just an excuse to get a sawzall. They are great.

 

[jd4242]

I would pick up a grinder and some cut off wheels.will come in very handy, know I've used it more than a sawzal on my rig.

 

[Anime]

Whatever saw you use, I'd suggest cutting horizontally about 1/4-1/2" BELOW where you want the new edge to be, THEN folding that additional material up and back 90 degrees. This will make a lip that will give rigidity to that panel and keep it from being weak and flimsy. You also might want to use a file and smooth out any burrs and take the sharp edge off so you don't cut yourself or so someone else doesn't harm themselves on that edge. It can also be a good idea to use some trim paint or tape off everything else and spray paint the bare metal of the cut edge so it doesn't rust.

A reciprocating saw would be preferable, those mini 12V cordless ones are great for such stuff, but a jigsaw with a long enough blade will be fine. You can always use tape and newspaper on the top panel to give some cushion to the jigsaw base so you can have it against the body and not scrape up the paint.

 

[Eddie94]

EXACTLY what I had in mind.

 

[Eddie94]

 

[frankcal]

Nice job on the cutting. That color looks really sweet I'm liking it

 

[obie]

Wow, looks awesome now! Good job

 

[Four0Sport]

now you need to ditch the bumper for something more aesthetically pleasing to your chopped quarter lowers

 

[Eddie94]

yeah definitely, I know a guy who does a lot of fabricating for off-road stuff, and if I can't get him to build me one then I've got my eye on one of these

(http://www.explorerforum.com/forums/showthread.php?t=282724)

 

[siguaw]

I'd suggest cutting horizontally about 1/4-1/2" BELOW where you want the new edge to be, THEN folding that additional material up and back 90 degrees. This will make a lip that will give rigidity to that panel and keep it from being weak and flimsy.

Good idea. I was looking into doing this too and it was nice to see how others have done it before I i went at it with whatever torch,hammer, tin snips or saw where just laying around