Getting a feeler for which tool would be best for getting an easy clean cut on factory fender.

Dremel? Jigsaw? Hand saw?
Include info like type of blade, ease of use or difficulty.

What did you use? Post pictures with the edge and finished product if you have em!!

 

Really solid write up here.
Project-JK.com - Jeep JK Wrangler Resource » Jeep JK Wrangler Factory Fender Chop

 

I've been over that multiple times, just seeing if there is a better or easier way...I'm going to purchase a new toy to chop mine so I want other peoples opinions just to think about.

 

Nice sunny day and a box blade works well. No sanding required.. Also a rotozip with a metal blade works pretty well.

 

I used the cheap roto tool from harbor freight. Cuts like melted butter!

 

Gotcha!

 

Here's my suggestions : Tape up your lines with blue or white painters tape and leave it for a couple of days relooking and retaping until happy with all, then break out the fun tools. I used a dremel (wasn't powerful enough), jigsaw (too unsteady) and found using a grinder with a 6" cut-off wheel is the PERFECT tool, it slices easily and accurately through the plastic fenders, and then a hand hacksaw for the corner parts near the body (I let my son finish it below).

I'd suggest cutting and removing in small sections (esp the box section around the sidelight) and cut the excess away first and then cut on the exact desired line later.

If you're keeping the inners, chop them very gradually and AFTER the outers. I chopped too much inner on first fender.

A cheap heat gun will melt the door edging glue (add superglue it if doesn't stick) and melt the corners for a finished look. I bought 25-foot and used almost all.

Not much else to tell. Check out WOL's write-up also.

These are 2009 photos :

 

I used a jigsaw with a metal blade. The cutting wheel cut great but spins so fast it melts the plastic. I used a cheese grater looking thing ( dont know name but used in bondo application) to smmoth out any imperfections. The door trim will not hold for long so have some adhesive ready. I used an epoxy and it has not budged since. I cut the inners with a zip wheel.

 

This and beer.....hahahaha

 

My favorite, and my second favorite.....