Jeff Patterson
Observer
These will be a GREAT addition to my rig! When will they go on sale?
Barn Door for JK factory hardtops
- Thread starter jscherb
- Start date
These will be a GREAT addition to my rig! When will they go on sale?
jscherb
Expedition Leader
The company hasn't told me exactly, but it should be any time now. The window being installed in the hardtop in the photo earlier today is a production window.
jscherb
Expedition Leader
I've been asked a number of times whether the flat fenders have more tire clearance than the factory fenders. Here's a pair of photos taken at different times but from pretty much the same angle that shows the difference. You can see that the bottom of the flat fender is roughly at the center of the headlight/bottom of the top door hinge, and the bottom of the factory fender is near the bottom of the headlight/more near the center of the two door hinges.
There are a few reasons for this... first the flat fender is actually flat and level, while the factory fender slopes about an inch and a half from the body to the edge of the fender. And, the vertical face of the flat fender is about 1 5/8" tall, while the vertical face of the factory fender is just under 3" tall. The combined result of those differences is roughly 3", but I can measure it exactly as I do the next install.
Or, looking at the same math another way, the flat fenders have pretty much the same clearance as if the factory fenders had the entire vertical face trimmed off.
There are a few reasons for this... first the flat fender is actually flat and level, while the factory fender slopes about an inch and a half from the body to the edge of the fender. And, the vertical face of the flat fender is about 1 5/8" tall, while the vertical face of the factory fender is just under 3" tall. The combined result of those differences is roughly 3", but I can measure it exactly as I do the next install.
Or, looking at the same math another way, the flat fenders have pretty much the same clearance as if the factory fenders had the entire vertical face trimmed off.
jscherb
Expedition Leader
Fiberglass parts always stay in the mold to cure overnight, so the first thing to do the next morning is to take the part out of the mold. I've never done a video of that process so I thought some might be interested in seeing it happen.
Since these are two part molds, the first step is to remove all of the bolts holding the two parts of the mold together. Then the first part of the mold is removed, and after that the part almost falls out of the other half of the mold...
The part has mold release on it that has to be washed off (this mold release is water soluble), and the edges have to be trimmed. Also since the fender was made in a two-part mold, there's a bit of flash at the parting line that gets sanded off and buffed. I'll do all of that today, photos to come.
Since these are two part molds, the first step is to remove all of the bolts holding the two parts of the mold together. Then the first part of the mold is removed, and after that the part almost falls out of the other half of the mold...
The part has mold release on it that has to be washed off (this mold release is water soluble), and the edges have to be trimmed. Also since the fender was made in a two-part mold, there's a bit of flash at the parting line that gets sanded off and buffed. I'll do all of that today, photos to come.
jscherb
Expedition Leader
Trimming the fenders starts with a gauge block to mark the trim line. I put tape on the fender because the line will be hard to see on the black fiberglass.
Preliminary trimming. I'll do the final trimming when I install them on the Jeep:
Since I molded the mounting flange on factory fenders, there are witness marks showing exactly where to drill the mounting holes. For accuracy, I always drill a small pilot hole first.
I made up a template for drilling for the marker lights. I'm using CJ markers, but I also made the template for YJ markers.
On the underside of the fenders I molded in lugs to zip-tie the marker light wiring out of harm's way.
Next I'll wash off most of the mold release and test fit them.
Preliminary trimming. I'll do the final trimming when I install them on the Jeep:
Since I molded the mounting flange on factory fenders, there are witness marks showing exactly where to drill the mounting holes. For accuracy, I always drill a small pilot hole first.
I made up a template for drilling for the marker lights. I'm using CJ markers, but I also made the template for YJ markers.
On the underside of the fenders I molded in lugs to zip-tie the marker light wiring out of harm's way.
Next I'll wash off most of the mold release and test fit them.
jscherb
Expedition Leader
A flat fender bolted up to check the fit. I hadn't washed all the mold release at the point these photos were taken.
I also haven't trimmed the front gusset yet, I'll do that when I do the install on the Jeep.
After test-fitting, I cleaned the rest of the mold release off, removed the flash at the mold joint and buffed where I removed the flash. I'll do a little more buffing after installation and final trimming, but they're not looking too bad at this point.
I also haven't trimmed the front gusset yet, I'll do that when I do the install on the Jeep.
After test-fitting, I cleaned the rest of the mold release off, removed the flash at the mold joint and buffed where I removed the flash. I'll do a little more buffing after installation and final trimming, but they're not looking too bad at this point.
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shortbus4x4
Expedition Leader
Wow, nice. The little details like the lugs for the marker light wiring is what separates the men from the boys.
Comanche Scott
Expedition Leader
Nice work Jeff.
Will you cut off the factory metal bracket that holds the original finder under the top of the wheel arch?
Will you cut off the factory metal bracket that holds the original finder under the top of the wheel arch?
jscherb
Expedition Leader
No, I'm using them for their factory-intended purpose - they're part of the support structure for the flat fenders.
jscherb
Expedition Leader
More pictures of the flat fenders.
The marker light is illuminated in this next photo although it's a little hard to tell because it's daylight. The fenders are designed to accept '72-'86 CJ marker lights or '87-'95 YJ marker lights, but any other light that's a good size could be installed. I used CJ markers on these.
The marker light is illuminated in this next photo although it's a little hard to tell because it's daylight. The fenders are designed to accept '72-'86 CJ marker lights or '87-'95 YJ marker lights, but any other light that's a good size could be installed. I used CJ markers on these.
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TrailBadger
Banned
One more test you might need to check.. to see if there any fender flap or shake while driving.. The last time I had a 63 Bug.. I mounted those Baja fenders on the front and they flapped almost like wings.. purely made from an inferior material.. unlike your flats.