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.

 

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 installed the flat fenders today.

 

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.

 

A few more.







I reused the factory inner fender liners. A few small mods to the liners were required.

 

And finally, almost everything I design and build gets the 225-lb. gorilla test, and these fenders are no exception...

 

It's amazing what you do because the same type of innovation and strength seem to elude the factory.

 

Thanks but don't be too hard on the Jeep engineers - they have to juggle many competing priorities - costs, US and global safety and other vehicle regulations, production schedules, the demands of their marketing people, etc. Many of the things that I do and the automotive aftermarket does wouldn't do well with some of those competing priorities.

What surprises me is that in the 10 years since the JK has been on the market, no company has produced true flat fenders yet. Maybe my fenders are a dumb idea that nobody will like, but seems to me echoing the original Willys MB flat fenders is a natural thing to do.

 

These Flat Fenders "should " be a Hot Item, they have the Right Look, and are as sturdy
as the original flats were . Everyone with the "Willys" edition needs these, they're true to the Heritage of the JK.
Fabulous Job, thanks for putting them out for all to admire !

 

Maybe I already requested this but here I go again. Add me to the list for testing, I would buy a proto type set.