Well, I accomplished a lot this weekend. Got the rear fenders cut and done, for the most part. I left the lower ends unfinished incase i need to raise the flare some in order to run a lower ride height. Should have some bump stops coming in this week so maybe I can get figured out during the week. Anyway here are some pics.
Pics jump between passenger and drivers side but same concept...
Since I had my kelcos holding on my fenders i masked everything and traced my lines. The top of my flare is 3.75 up from the bottom of the oem fender.
Taped the fender and marked the top with a sharpie and came down 7/8" from there and made the lower mark. Before I cut anything i installed my blind nuts, i used metric 5mm but I would have used 6mm if my tool would do them. It will do aluminum 6mm but not steel. Anyway 5mm is plenty. I couldn't get 1 of them in there at full depth until I cut the fender. Putting them in before you cut helps to not bend the fender.
Next, cut the lower mark and begin pealing it down.
Should end up with something like this
Next, I cut little slits in the inner fender to let it conform easier. Slap it with a hammer (carefully, take your time) and the inner will meet the outer. Once its in place weld the BOTTOM side, just a tack were the outer fender meets the inner fender IN THE SLOTS YOU CUT. IF you were to weld it from the top when you go to bend the rest up (assuming you do as I have done) it will make it stick out to much, for my taste at least.
In this pic you can see where I am talking about tack welding it.
Now you have something like this.
Next, I took my plasma cutter and cut the tabs to about 3/8" long or so. Then i took a 5 pound sledge (used it as a dolly on the backside of the fender) and a ball-peen hammer and worked the lip up and over and welded it together. The Drivers side turned out a lot better than the passenger side one pictured, but the photo was better of the passenger side. Note that if you leave the tabs to long, when you bend them up they will be close to the top of your fender flare, you don't want this because when you weld it the heat will mess up your paint. I used my tig welder on pulse to keep the heat low but i guess a mig and a copper spoon would do too...
Here is the passenger side.
And the Drivers side, not finalized in this pic but you can see where its going.
Here is a pic of my blind nut tool.
Ok its time for beer and asprin.