Flat fender flares on an XJ require cutting the factory sheet metal for clearance before mounting. If you are looking for a rugged, off-road-ready look for your Jeep XJ, installing jeep xj fender flares flat is a popular modification that offers both style and function. These flares provide extra tire coverage while giving your Cherokee a more aggressive stance, but the installation process demands precision and patience.
This guide walks you through everything you need to know about flat fender flares for the Jeep XJ, from choosing the right set to cutting your fenders and bolting everything on. Whether you are a seasoned DIYer or a first-time modifier, you will find practical steps and tips to get the job done right.
Understanding Flat Fender Flares For The Jeep Xj
Flat fender flares differ from stock flares in both design and purpose. Stock flares are curved and molded to follow the factory body lines, offering minimal clearance for larger tires. Flat flares, on the other hand, sit flush against the fender and extend outward, creating a flat, boxy look that complements the XJ’s angular design.
These flares are typically made from durable materials like ABS plastic, fiberglass, or steel. They are designed to withstand trail abuse, rocks, and branches, making them ideal for off-road use. Most flat flare kits require cutting the factory sheet metal to achieve the necessary clearance, which is why they are often called “cut-out” flares.
Benefits Of Flat Fender Flares
- Increased tire clearance for up to 35-inch tires without rubbing
- Improved off-road performance by allowing full suspension articulation
- Aggressive, custom look that sets your XJ apart
- Durable construction that resists cracking and fading
- Easy to clean and maintain compared to stock flares
Common Materials Used
- ABS Plastic: Lightweight, affordable, and easy to paint. Prone to cracking under extreme impact.
- Fiberglass: Stronger than plastic, but heavier. Requires careful installation to avoid stress fractures.
- Steel: Extremely durable and dent-resistant. Adds significant weight and may rust over time.
Jeep Xj Fender Flares Flat
When shopping for Jeep Xj Fender Flares Flat, you will find several brands and styles. Popular options include the Bushwacker Flat Style flares, the Rugged Ridge Xtreme flares, and custom-made fiberglass units. Each brand has its own mounting system and cutting template, so read the instructions carefully before starting.
Most flat flare kits come with the flares themselves, mounting hardware, and a cutting template. Some kits also include a trim piece to cover the raw edge of the cut metal. You will need basic tools like a jigsaw, drill, measuring tape, and safety gear.
What To Look For In A Kit
- Clear and accurate cutting template
- Stainless steel or zinc-plated hardware to prevent rust
- UV-resistant material to avoid fading
- Good customer reviews regarding fitment and durability
Preparing For Installation
Before you start cutting, gather all necessary tools and materials. You will need a jigsaw with a metal-cutting blade, a drill with various bits, a marker or chalk, measuring tape, a socket set, and safety glasses. It is also wise to have a friend help you hold the flares in place during test fitting.
Park your XJ on a level surface and remove the stock fender flares. This usually involves prying off plastic clips or removing screws from the inner fender liner. Clean the fender area thoroughly to remove dirt and debris that could interfere with the template.
Step-By-Step Preparation
- Remove the stock flares and all mounting hardware.
- Remove the inner fender liners if they are in the way.
- Clean the fender edges with degreaser and let dry.
- Test fit the new flat flares to see how they align.
- Mark any interference points with chalk.
Cutting The Factory Sheet Metal
This is the most critical part of the installation. The cutting template provided with your kit will show you exactly where to cut. If no template is included, you can create your own by tracing the flare onto the fender with a marker, leaving a 1/2-inch margin for error.
Use a jigsaw with a fine-tooth metal blade to cut along the marked line. Go slow and steady to avoid tearing the metal. Wear safety glasses and gloves to protect yourself from sharp edges. After cutting, file down any burrs or sharp spots to prevent injury and ensure a clean fit.
Tips For A Clean Cut
- Use a cutting oil to reduce heat and blade wear.
- Cut from the inside of the fender for better control.
- Make relief cuts at corners to avoid binding the blade.
- Test fit the flare frequently to avoid cutting too much.
Mounting The Flat Fender Flares
Once the sheet metal is cut, you can mount the flat flares. Most kits use bolts or rivets to secure the flares to the fender. Some flares also use adhesive tape along the inner edge for a tighter seal. Follow the manufacturer’s instructions for your specific kit.
Start by holding the flare in place and marking the mounting holes. Drill pilot holes through the fender at these marks. Then, attach the flare using the provided hardware. Tighten the bolts evenly to avoid warping the flare. If your kit includes a trim piece, install it now to cover the cut edge.
Common Mounting Methods
- Bolt-on: Uses bolts and nuts for a secure fit. Allows easy removal later.
- Rivet-on: Uses rivets for a permanent, clean look. Harder to remove.
- Adhesive-only: Less common for flat flares. Not recommended for off-road use.
Wiring And Clearance Considerations
After mounting the flares, check for tire clearance. Turn the steering wheel lock-to-lock and cycle the suspension to ensure the tires do not rub the flares or the cut metal. If you have oversized tires, you may need to trim additional metal or adjust bump stops.
If your XJ has factory wiring for turn signals or marker lights, you may need to relocate these when installing flat flares. Some flat flare kits include LED lights that mount directly to the flare. Otherwise, you can splice the factory wiring and mount small lights to the flare or bumper.
Relocating Wiring
- Disconnect the battery to avoid shorts.
- Remove the factory light housings from the stock flares.
- Extend the wiring if needed using heat-shrink connectors.
- Mount aftermarket lights to the flat flares or nearby body panels.
- Test all lights before reassembling.
Painting And Finishing
Most flat flares come in a black textured finish, but you can paint them to match your XJ’s body color. Use a plastic adhesion promoter if the flares are ABS or fiberglass. Clean the surface with wax and grease remover, then apply primer, base coat, and clear coat for a durable finish.
If you prefer a matte or satin look, you can skip the clear coat. For steel flares, apply a rust-inhibiting primer before painting. Allow each coat to dry completely before applying the next. This step can take a few days but is worth the effort for a professional appearance.
Paint Options
- Body color match for a seamless look
- Black textured for a rugged, off-road aesthetic
- Custom colors like red, blue, or green for a unique style
Maintenance And Care
Flat fender flares require minimal maintenance. Wash them with soap and water during regular car washes. Avoid using abrasive cleaners that could scratch the surface. If the flares are painted, wax them occasionally to protect the finish.
Check the mounting hardware periodically for looseness, especially after off-road trips. Tighten any loose bolts or rivets to prevent the flares from vibrating or coming off. If you notice rust on steel flares, sand it down and repaint the affected area.
Common Issues And Fixes
- Flares cracking: Use a plastic repair kit for ABS or fiberglass.
- Hardware rusting: Replace with stainless steel bolts.
- Flares fading: Apply a UV protectant spray.
Frequently Asked Questions
Do I need to cut my fenders for flat flares?
Yes, most flat fender flares require cutting the factory sheet metal for proper clearance. The amount of cutting depends on the kit and tire size.
Can I install flat flares without removing the stock flares?
No, you must remove the stock flares first. The flat flares mount directly to the fender and require the old flares to be out of the way.
Will flat flares affect my XJ’s resale value?
It depends on the buyer. Some prefer the stock look, while others value the off-road capability. Keep the original flares if you plan to sell later.
How much do flat fender flares cost for a Jeep XJ?
Prices range from $200 to $600 depending on material and brand. Steel flares are usually more expensive than plastic ones.
Can I use flat flares with stock tires?
Yes, but they will look oversized and may not provide functional benefits. Flat flares are best paired with larger tires for clearance.
Final Thoughts On Installing Flat Fender Flares
Installing jeep xj fender flares flat is a rewarding project that transforms the look and capability of your Cherokee. The process involves careful cutting, precise mounting, and attention to detail, but the results are well worth the effort. You will gain extra tire clearance, a rugged appearance, and the satisfaction of a job done yourself.
Take your time with the cutting step and double-check measurements before making any cuts. If you are unsure, practice on a scrap piece of metal first. With the right tools and patience, you can complete the installation in a weekend and hit the trails with confidence.
Remember to follow all safety precautions and wear protective gear. If you encounter any issues during installation, consult online forums or the manufacturer’s support team. Your XJ will thank you for the upgrade, and you will enjoy many miles of off-road adventures with your new flat fender flares.