Many people have asked just how much I had to trim to fit 35x12.5's on my new model explorer when I only had ~4.5" of lift.
I figure a picture is worth a thousand words so:
Front End:
Red arrow indicates start of modification. By the bottom I think 3-3.5" are removed from stock.
Red arrow showing where I removed pinch weld
Bumper modifications. Bolts are holding plastic to the metal 'frame'
Rear End:
Red arrows showing where I bent the metal edges away from the tire
Rear trim modifications
With this current setup I have eliminated all audible rubbing with the exception of when I stuff a front tire all the way up. Then its only very minor, and not very often. In the rear it still touches the front of the wheel well but I don't want to cut that for fear it will look bad. The rear also touches the top of the inner well at full stuff
A Detailed How To:
Step 1: buy old 35" tires, mount tires, 'hack' away at where you KNOW it will rub.
Step 2: take offroad, flex, etc . . . making notes of where the current tires rub
Step 3: mark with tape where it still rubs and accomidate for more tread on new tires.
Step 4: Trimming:
A: Front:
Fenders
For the fenders I taped where I wanted the new fold, removed from vehicle and used a jigsaw, sawzall, hacksaw, and whatever else I could find
shoot: 
) . . .leaving an inch of 'unwanted' metal to create a new fold. I then used vise-grips and folded the remaining metal over.
I then used a sawzall on the pinch weld, and welded the fresh cut back up (no negative effects so far)
Remount fenders
Bumper
Mark bumper with tape. Remove bumper, drill out rivets drilling through bumper. Install bolt washers and nut where rivet was. Cut bumper along tape with circular saw (makes for a straighter edge) or sawzall.
B: Rear:
Remove tire. Take a BFH to any metal causing rubbing.
Mark rear trim with tape. Remove rear trim (two nuts, two 'push-pins', and three plastic 'clips') Take sawzall to metal beneath trim. Use jigsaw/circular saw on trim. Replace trim.
Step 5: Test offroad, flex, etc. Note rubbing. Repeat any necessary steps from above.
Step 6: Spend your months salary on tires. mount tires. Take offroad. Flinch and :fire: and curse :frustrate as you tear up your new investment in tires because they rub. . . Note rubbing. Repeat any necessary steps from above. (Note: I wouldn't suggest repeating any of step 6 )
I figure a picture is worth a thousand words so:
Front End:
Red arrow indicates start of modification. By the bottom I think 3-3.5" are removed from stock.
Red arrow showing where I removed pinch weld
Bumper modifications. Bolts are holding plastic to the metal 'frame'
Rear End:
Red arrows showing where I bent the metal edges away from the tire
Rear trim modifications
With this current setup I have eliminated all audible rubbing with the exception of when I stuff a front tire all the way up. Then its only very minor, and not very often. In the rear it still touches the front of the wheel well but I don't want to cut that for fear it will look bad. The rear also touches the top of the inner well at full stuff
A Detailed How To:
Step 1: buy old 35" tires, mount tires, 'hack' away at where you KNOW it will rub.
Step 2: take offroad, flex, etc . . . making notes of where the current tires rub
Step 3: mark with tape where it still rubs and accomidate for more tread on new tires.
Step 4: Trimming:
A: Front:
Fenders
For the fenders I taped where I wanted the new fold, removed from vehicle and used a jigsaw, sawzall, hacksaw, and whatever else I could find
shoot: ) . . .leaving an inch of 'unwanted' metal to create a new fold. I then used vise-grips and folded the remaining metal over.I then used a sawzall on the pinch weld, and welded the fresh cut back up (no negative effects so far
)Remount fenders
Bumper
Mark bumper with tape. Remove bumper, drill out rivets drilling through bumper. Install bolt washers and nut where rivet was. Cut bumper along tape with circular saw (makes for a straighter edge) or sawzall.
B: Rear:
Remove tire. Take a BFH
to any metal causing rubbing.Mark rear trim with tape. Remove rear trim (two nuts, two 'push-pins', and three plastic 'clips') Take sawzall to metal beneath trim. Use jigsaw/circular saw on trim. Replace trim.
Step 5: Test offroad, flex, etc. Note rubbing. Repeat any necessary steps from above.
Step 6: Spend your months salary on tires. mount tires. Take offroad. Flinch and :fire: and curse :frustrate as you tear up your new investment in tires because they rub. . .
Note rubbing. Repeat any necessary steps from above. (Note: I wouldn't suggest repeating any of step 6 )
