Installing flat fender flares on a Jeep XJ provides additional tire clearance for larger off-road wheels. If you are looking to upgrade your Cherokee’s look and performance, Jeep XJ flat fender flares are a smart modification. They give your rig a more aggressive stance while preventing tire rub on the trail.
Flat fender flares replace the factory rounded arches. They sit flush against the body and extend outward. This design creates a flat surface that allows for bigger tires without lifting the suspension too high. Many off-roaders prefer this style for its clean, utilitarian look.
In this guide, we will cover everything you need to know about choosing, installing, and maintaining these flares. You will learn about materials, fitment, and common mistakes to avoid. Let’s get started.
Why Choose Jeep Xj Flat Fender Flares
The stock fenders on a Jeep XJ are restrictive. They limit tire size to around 31 inches without major trimming. Flat fender flares solve this problem by giving you more room. They also protect your vehicle from mud and debris.
Another reason is aesthetics. Flat flares give the XJ a boxier, more purposeful look. They match the Cherokee’s angular design better than rounded flares. Plus, they are easier to clean and less likely to catch on branches.
Durability is also a factor. Most flat flares are made from tough materials like ABS plastic or fiberglass. They can take a beating on rocky trails without cracking. This makes them ideal for serious off-road use.
Jeep Xj Flat Fender Flares
Now let’s talk about the different types available. Jeep XJ flat fender flares come in several styles. Some are designed for cutting the factory metal, while others bolt directly over the existing fenders. Knowing the difference helps you choose the right set for your build.
Bolt-On Vs Cut-Out Flares
Bolt-on flares attach over your existing fenders. They are easier to install but add width. Cut-out flares require you to trim the factory metal. This gives a cleaner look and more clearance. Both have pros and cons.
Bolt-on flares are great for beginners. You don’t need to cut your Jeep’s body. They simply screw into place. However, they can look bulky. Cut-out flares look more integrated but require careful measuring and cutting.
Material Options
Most flat fender flares are made from ABS plastic, fiberglass, or steel. ABS plastic is lightweight and flexible. It resists cracking and is easy to paint. Fiberglass is stiffer but can shatter on impact. Steel flares are heavy but nearly indestructable.
For most off-roaders, ABS plastic is the best choice. It balances weight, durability, and cost. Steel is overkill for a daily driver. Fiberglass is best for show trucks that see light trail use.
Width And Tire Clearance
Flat flares come in different widths. Common sizes are 2-inch, 4-inch, and 6-inch. A wider flare gives more tire coverage. This is important if you run large tires like 35s or 37s. Check local laws, as flares must cover the tire tread.
Measure your tire width before buying. You want the flare to extend past the tire sidewall. A good rule is to add 2 inches of flare width for every inch of tire over 33 inches. This prevents legal issues and keeps mud off your windows.
Preparing For Installation
Before you start, gather your tools and materials. You will need a drill, rivet gun, measuring tape, marker, and safety glasses. For cut-out flares, you also need a cutting wheel or jigsaw. Take your time with prep work.
Clean the fender area thoroughly. Remove any dirt or rust. This ensures the flares sit flat. If you are painting the flares, do it before installation. Let the paint cure for at least 24 hours.
Step-By-Step Installation Guide
Follow these steps for a clean install. The process varies slightly between bolt-on and cut-out flares. We will cover both methods.
- Remove the factory flares if present. They are usually held by clips or screws.
- Test fit the new flares. Hold them in place and check alignment. Mark the mounting holes with a marker.
- Drill pilot holes at your marks. Use a bit slightly smaller than your rivets or screws.
- For cut-out flares, trace the inner edge onto the fender. Cut along the line with a cutting wheel. Smooth the edges with a file.
- Attach the flares using rivets or bolts. Start from the center and work outward. Tighten evenly to avoid warping.
- Seal the edges with silicone caulk. This prevents water and dirt from getting behind the flare.
If you are using cut-out flares, double-check your cuts. Measure twice, cut once. A mistake here can ruin your fender. Take your time and work slowly.
Common Installation Mistakes
Many people rush the installation. This leads to misaligned flares or gaps. Always test fit before drilling. Another mistake is using the wrong fasteners. Use stainless steel rivets or bolts to prevent rust.
Do not overtighten the fasteners. This can crack plastic flares. Snug them up, then check for gaps. If you see a gap, loosen and adjust. A perfect fit takes patience.
Also, consider using a backing plate. Some flares come with metal strips that reinforce the mounting points. If yours don’t, you can buy them seperately. They prevent the flare from pulling through the plastic.
Legal Considerations For Flat Fender Flares
Before installing, check your local laws. Some states require fender flares to cover the tire tread. Others have rules about how far the tire can stick out. Flat flares usually meet these requirements if you choose the right width.
In most areas, the tire must be covered from the top view. This means the flare should extend past the widest part of the tire. If your tires stick out too far, you might get a ticket. Measure carefully.
Also, some off-road parks have rules about tire coverage. They may require flares for entry. Flat fender flares are a good way to stay legal while maximizing clearance.
Painting And Finishing Your Flares
Most flat fender flares come in black or raw material. You can paint them to match your Jeep’s color. Use a flexible primer and paint designed for plastic. This prevents peeling and chipping.
Clean the flares with soap and water. Then scuff them with fine-grit sandpaper. Apply primer, let it dry, then paint. Use light coats to avoid drips. Finish with a clear coat for UV protection.
If you prefer a rugged look, leave them black. Textured black flares hide scratches well. Many off-roaders choose this option for a low-maintenance finish.
Maintenance And Care
Flat fender flares require minimal maintenance. Wash them with soap and water to remove mud. Check the fasteners occasionally for looseness. Tighten any that have worked free.
If you crack a flare, you can repair it with plastic epoxy. Clean the area, apply the epoxy, and clamp it. Sand and paint if needed. For steel flares, use a welder or body filler.
Inspect the seals around the flares. Over time, silicone can crack. Reapply if you see gaps. This prevents water from getting into the body panels and causing rust.
Benefits Over Other Fender Options
Flat fender flares offer several advantages over tube fenders or stock flares. They are lighter than steel tube fenders. They also provide more coverage than tube designs, which can leave tires exposed.
Compared to stock flares, flat flares are stronger and more functional. They don’t crack as easily in cold weather. They also allow for larger tires without a huge lift. This keeps your center of gravity lower.
Another benefit is cost. Flat fender flares are affordable compared to custom metalwork. A good set costs between $200 and $500. Installation is DIY-friendly, saving you labor costs.
Popular Brands And Products
Several brands make quality flat fender flares for the Jeep XJ. Bushwacker is a popular choice. They offer bolt-on flares in various widths. Their ABS plastic is durable and easy to paint.
Another brand is Rugged Ridge. They make cut-out flares that fit tight to the body. Their design is simple and effective. Many off-roaders trust their products for trail use.
For a budget option, look at eBay or Amazon. Some generic brands offer good value. Just check reviews for fitment issues. Cheap flares might not align perfectly.
Custom fabrication is also an option. Some shops make flares from aluminum or steel. These are more expensive but offer a unique look. If you have welding skills, you can make your own.
Combining Flares With A Lift Kit
Flat fender flares work best with a lift kit. A 3- to 4-inch lift allows for 33-inch tires with minimal trimming. For 35s, you need a 4.5- to 6-inch lift. The flares give you the extra room needed for articulation.
Without a lift, flat flares still help. They allow you to run slightly larger tires than stock. But for serious off-roading, a lift is recommended. The combination gives you ground clearance and tire clearance.
When choosing a lift, consider your driving style. A budget boost is cheap but limits travel. A long-arm lift offers better flex. Match the lift to your flare width for best results.
Frequently Asked Questions
Q: Can I install flat fender flares without cutting my Jeep?
A: Yes, bolt-on flares attach over the existing fenders. No cutting is needed. Cut-out flares require trimming the metal.
Q: What size tires can I run with flat fender flares?
A: It depends on the flare width and lift. With 4-inch flares and a 4-inch lift, you can run 33-inch tires. For 35s, use 6-inch flares.
Q: Are flat fender flares legal on the road?
A: In most states, yes, as long as they cover the tire tread. Check your local laws for specific requirements.
Q: How do I remove old factory flares?
A: Factory flares are held by clips and screws. Pry them off carefully. Some may have adhesive. Use a heat gun to soften it.
Q: Do flat fender flares affect fuel economy?
A: Slightly. The added width creates drag. But the effect is minimal, especially compared to larger tires.
Final Thoughts On Upgrading
Installing flat fender flares is one of the best mods for a Jeep XJ. It improves looks, clearance, and protection. Whether you choose bolt-on or cut-out, the process is straightforward.
Take your time with the installation. Measure everything twice. Use quality fasteners and sealant. A well-installed set of flares will last for years.
Remember to check your local laws before driving on the road. With the right setup, your XJ will look tough and perform better on the trail. Flat fender flares are a practical upgrade that pays off every time you hit the dirt.
If you have questions, ask in the comments or join a Jeep forum. The community is helpfull and full of tips. Happy wheeling.