The Ultimate Guide to How to Cut Jeep XJ Fenders: Step-by-Step Instructions

The Jeep XJ Cherokee, a classic off-roader known for its ruggedness and versatility, can be further enhanced by modifying its appearance with a wider stance. One popular method involves cutting the factory fenders, allowing for larger tires and a more aggressive look. This guide will walk you through the process of how to cut Jeep XJ fenders, providing step-by-step instructions and essential tips to achieve a professional finish.

Why Cut Your Jeep XJ Fenders?

Cutting your fenders offers several advantages, including:

• Increased Tire Clearance: By removing the restrictive factory fender wells, you can fit larger tires, improving off-road performance and ground clearance.
• Enhanced Aesthetics: A wider stance with larger tires gives your XJ a more aggressive and rugged appearance, enhancing its off-road persona.
• Improved Approach and Departure Angles: Cutting the fenders can improve your XJ’s approach and departure angles, allowing you to tackle more challenging terrain.
• Customization: Cutting your fenders opens up a world of customization possibilities, allowing you to create a unique and personalized look for your XJ.

Safety First: Essential Gear and Preparation

Before embarking on this project, ensure you have the necessary tools and safety gear:

• Safety Glasses: Protect your eyes from flying debris.
• Gloves: Protect your hands from sharp edges and potential cuts.
• Hearing Protection: Reduce noise levels during cutting and grinding.
• Cutting Tool: A reciprocating saw with a metal-cutting blade is ideal for this task.
• Grinder: A grinder with a sanding disc is essential for smoothing out rough edges.
• Measuring Tape: Accurate measurements are critical for a symmetrical cut.
• Marking Tool: A marker or chalk is useful for marking the cutting lines.
• Work Area: Choose a well-ventilated area with a stable work surface.

Planning Your Cut: Determining the Right Amount of Fender Removal

The amount of fender you remove is crucial for achieving the desired look and tire clearance. Consider the following factors:

• Tire Size: Determine the maximum tire size you want to run.
• Fender Flare Style: Consider the style of fender flares you plan to install (if any).
• Desired Look: Decide on the level of “chop” you want to achieve, from a subtle trim to a full-blown “flat fender” look.

Marking the Cutting Lines: Precision is Key

1. Measure and Mark: Carefully measure the desired amount of fender removal, ensuring symmetry on both sides.
2. Use a Straight Edge: A straight edge or ruler helps create precise cutting lines.
3. Mark the Cutting Lines: Use a marker or chalk to clearly indicate the cutting lines on both fenders.

Cutting the Fenders: Taking Your Time and Patience

1. Secure the Vehicle: Ensure your XJ is securely supported on jack stands with the parking brake engaged.
2. Start Cutting: Use the reciprocating saw to carefully cut along the marked lines.
3. Work Slowly and Carefully: Avoid rushing the cutting process, as a clean cut is essential for a professional finish.
4. Protect Surrounding Areas: Use masking tape or cardboard to shield surrounding areas from accidental cuts.

Smoothing Out the Edges: Achieving a Professional Look

1. Grind the Edges: Use a grinder with a sanding disc to smooth out the raw edges of the cut fenders.
2. Remove Sharp Edges: Pay extra attention to removing any sharp edges that could cause injury.
3. Clean Up Debris: Remove any metal shavings or debris from the cutting and grinding process.

Installing Fender Flares: Completing the Transformation

1. Choose Your Flares: Select fender flares that complement your XJ’s style and provide the desired level of tire coverage.
2. Install the Flares: Follow the manufacturer’s instructions for installing the fender flares.
3. Secure the Flares: Ensure the flares are securely mounted and properly aligned.

Final Touches: Adding the Finishing Details

1. Paint or Bedliner: Paint or apply bedliner to the cut fenders for protection and a cohesive look.
2. Wheel and Tire Selection: Choose wheels and tires that fit the new fender clearance and enhance your XJ’s off-road capabilities.
3. Enjoy Your New Look: Take your modified XJ for a test drive and enjoy the enhanced off-road performance and aggressive new look.

The Final Chapter: Beyond the Cut

Cutting your XJ’s fenders is just the beginning of a journey of customization. You can further enhance your build with:

• Lift Kit: A lift kit will provide additional ground clearance and allow for even larger tires.
• Armor: Adding armor to your XJ’s undercarriage and body will protect it from off-road hazards.
• Accessories: Equip your XJ with essential off-road accessories like a winch, roof rack, and lights.

Questions You May Have

Q: Can I cut my Jeep XJ fenders without using a reciprocating saw?

A: While a reciprocating saw is the most common tool for cutting fenders, you can also use an angle grinder with a metal-cutting blade. However, this method requires more skill and care to achieve a clean cut.

Q: What type of fender flares should I use?

A: The choice of fender flares depends on your personal preference and the level of tire coverage you desire. Popular options include bolt-on flares, clip-on flares, and custom-made flares.

Q: How much does it cost to cut and flare my Jeep XJ fenders?

A: The cost of cutting and flaring your fenders can vary depending on the type of flares you choose, the labor involved, and any other modifications you make.

Q: Can I cut my Jeep XJ fenders myself?

A: Cutting your XJ’s fenders is a DIY project that can be done with the right tools and knowledge. However, it’s important to follow safety precautions and take your time to ensure a professional result.

Q: What are the legal implications of cutting my Jeep XJ fenders?

A: The legality of cutting your fenders can vary depending on your local regulations. It’s crucial to check with your local authorities to ensure compliance with any applicable laws.

Cutting your Jeep XJ fenders is a rewarding modification that can enhance its off-road performance, appearance, and overall capability. By following these steps and taking the necessary precautions, you can achieve a professional finish and enjoy the benefits of a wider stance and larger tires. Remember, safety comes first, and proper planning is key to a successful project.