Had some time last Saturday to get a project done on the truck. The front tires have been hitting the fenders hard when at full stuff. They were hitting the screws that hold the fender bulge and wheel well liner to the metal. I'd already ripped 3 of the bolts out. I didn't want to sacrifice any travel by getting taller bump stops (running factory right now), so I elected to trim both metal and plastic to gain space. The truck is no show truck....it's been through plenty, so had no hesitation in cutting off pieces.
First image shows full stuff with the plastic fender removed.
The plastic fenders and screws stick down at least another 1/2"
I marked and did a rough cut of about 1.25" all the way back to the cab. I left the front to blend in with the Brute Force bumper. After I confirmed clearance I went back and cleaned up the cut
Here's the final shape with everything cleaned up. I used a heat gun to reshape the fender liner as best I could. To attach it to the metal, I marked and drilled holes in the metal, then used some plastic trim clips from NAPA to pin the plastic to the inside of the metal. Worked fine. I smoothed all cut metal, and painted all exposed metal to help prevent rust.
I used self adhesive door edge molding to protect all metal edges
I cut the plastic fenders to match the contours of the metal cuts. They lose their mounting points when this work is done, but the plastic clips are strong enough to hold the fenders to the body. Looks much better now...gets rid of that heavy "eyebrow" look that the stock fenders give it.
Kind of hard to see with the whole truck being black
Overall not a bad job to do. I will likely need to cut and weld some on the firewall as well. Full stuff and full lock rub's, even with 33's and the caster increased way beyond spec. But I'll wait to do that until I get 35's. I'll probably need to trim more off the fenders at the same time.