Rear TJ flares on your sammi .

[sammi_davis]

First off you have to find a set of TJ flares . You can buy them new from 4wd hardware or find a jeeper upgrading to bushwhackers . TJ owners tend to replace the factory flares a lot as they fade easily . Black vinyl die does wonders for this . The aftermarket ones are supposed to be more UV stable ..time will tell .

This is a stock Tj rear flare
 

You will need to cut the "lip " off of the back of it so that it will sit flat on the side of the Zuk . I used a razor knife with a fresh point . It will take several passes , but it is pretty easy to cut .

 

Next you need to remove the centering pins . I used aviation snips to cut it off . Then I used the razor knife to smooth it down  .

 

This is what it will look like after you use the razor knife to clean it up.
 

Next is the fitting of the flare onto the sammi. I use welders vice grips to hold it in place and them I stand back to look at and see if "looks " ok . With the way I put mine on you do not see the round factory body lines from the old factory fender flares  .
  Once it is on place and you are happy with the fit , mark your holes to drill . The holes in the flare are oversized so you will be able to adjust the flare left and right and up and down after you install it .

 

 I used self tapping screws with washers to attach the flares to  the sammi .  I did drill a pilot hole to make it easier to put  the screws in . I found that a gear wrench works best for putting the screws in . 



Last  but not least is cutting the flare to fit the back body line . I didn't take a pic of the process ,but I will explain it .  I ran a piece of masking tape around the flare from the body to the inside lip . I then drew a line that was fairly level around the flare . Then I took the razor knife and cut it . Once you are through the flare you can use the aviation snips to trim the inner edge where it is thicker and difficult to cut . Here is a pic of the cut flare .



 I need to adjust the front up  a little , but the elongated mounting holes make that pretty easy . I still have to cut the inner fenders to take advantage of the larger flare also . But here is the finished pic of the flare installed on my Zuk .
 

[GeneralChaos]

Excellant article   

I'm getting some flares soon and you couldn't of writen a better article telling us how to install them.

Thanks
Steve

[sammi_davis]

No problem Steve , it was pretty easy . The fun part will be enlarging the wheelwell . Sami sheetmetal isnt too easy to weld up . My only advice is to take your time cutting .

[biker053]

are you planning on doing wrangler flares on all four corners using front wranglers in the front? if so can i get info on that or a link. thanks

[sammi_davis]

I dont have any flares on the front . I may put the front tjs I have on it , but no definite plans for it right now .

[bmp]

How would cherokee sport fender flares work?  I mean would they line-up and look as good as the tjs?

[colts_zuki]

I dont have any flares on the front . I may put the front tjs I have on it , but no definite plans for it right now .

 Why arent you gonna put any on the front? the rears look so good on your zuk dont you want matching fronts or is that the zuk thats choped up front?

[bmp]

That looks really good.  How much body trimming did you have to do to the fender well?

[sammi_davis]

Why arent you gonna put any on the front? the rears look so good on your zuk dont you want matching fronts or is that the zuk thats choped up front?

Its a tube front , to attach the flare you need a semi flat surface .

I am not sure how the Cherokee flares would work ... doesnt your buddy have a cherokee to steal a set off of and try them out ?

[bmp]

Sammi, You are good that is what I was thinking.   He decided to work on his jeep.  He started pulling the 4.2 and is going to drop in the 4.0.  While pulling the 4.2 found that the intake manifold had a crack in it.

[sierrafreak]

i am going to be putting some of those bushwhacker flares on my zook when i can get a hold of some
to buy them new they want $800 so i think i will try and find a wrecker with some but it should be simple seen it on a few zook's and the process might be the same

thanks for the write up hope i can apply it to what i want to do unless someone else has done what i want and has any extra tips

[bambbrose]

so you have to use YJ rear flares for the front and back?  In other words I need 4 rear flares?

[sammi_davis]

so you have to use YJ rear flares for the front and back?  In other words I need 4 rear flares?

I used TJ rears . YJ rears would work too though . I have seen TJs Front and Rear on OKIE-Zuks rig and it came out nice . With the tube clip I dont have many options for front flares .

[domba420]

we have 4 rear yj flares on one our zuks and they look pretty sweet, imo

[bambbrose]

Pics??