I found my Dremel didn't have enough oomph, I used an electric angle grinder with a 4.5" cut-off wheel, it sliced easily through both the inner and outer fenders and bracing.

I posted this on another thread :

- didnt see a reason to take the fenders off to cut them. When still on the Jeep they're supported and you can better see the cut lines you like.

- Best tool was an Angle Grinder with a thin 1/8 inch metal/ceramic cut-off wheel for slicing cleanly through. The plastic fenders are pretty thick and a dremel doesn't have enough oomph and a jigsaw cannot be well-controlled for a clean cut. Wear gloves, the angle grinder melts the plastic as it cuts through the line. I used a small hacksaw instead of grinder to cut through the plastic when near metalwork.

- Apply masking tape along the entire line of the fender including the radius and angles you'll be cutting. It's tempting to cut using sight only but tape will ensure straight lines and stop you hacking too much. My only regret is I hacked a little too much from one rear inner fender (I kept the inner pants to keep out rain and winter slush).

- Cut off the vertical overhanging plastic first and the bulky parts of inner fenders, then slice along your tape line for final cut. I kept the entire horizontal part of fender (keeping the radiused edge to retain fender strength) and sliced off the vertical part, and my tires still stick-out 2inches. Others have sliced the horizontal part much skinnier, but I'd guess their's bend and flex more at highway speed.

- Use a cheap heat-gun to melt the glue on the inside of the door-edge beading as you apply it. If the beading comes off later, add Gorilla glue. The beading does contract when hot (from heat gun or sun) and will then pop off the fender at the angles, so dont' stretch it to fit.

- WOL's write-up is excellent, much more detail than I wrote above.....

 

May I borrow your angle grinder ?

 

Of course, I should have made prior posts clearer. will PM

 

I'd be down for that. I have an 08 x that's pretty stock. And I live in Pleasantville. Maybe sometime towards the end of April. Sooner would be beter.

 

Here is the PIC

 

If you haven't already done it, check out the ecejs thread posted by rdy4rks.
Early April, great people and lots of fun.

 

hey guinness youre right by me! youre welcome to stop by sometime and check out my "test & tune" trails. we have some hills that are pretty tough and some nice spots to test out your arcticulation.

tried to take our polaris rzr out into the field last night, way too much snow. it rode up onto the snow untill the wheels weren't even touching the ground. luckily the rubi was heavy enough to get through and pull it back out.

 

Thanks for the offer. Keep an eye out for the Hudson Valley threads, we do some meet and greets and I have access to a few k acres up in sullivan county for trail rides.

 

will do! thanks

 

hey westchester folks... just wondering.. where are folk getting their work done? (eg. planning for the future). any recommendations in the lower westchester area (only shop i know of is in the bronx).