Installing flat fender flares on a Jeep Cherokee XJ provides extra tire clearance for larger wheels. If you are looking to upgrade your XJ’s stance and fit bigger tires without rubbing, Jeep Cherokee XJ flat fender flares are the solution. These flares replace the bulky factory plastic ones and give your rig a cleaner, more aggressive look.
Flat fender flares are a popular modification for off-road enthusiasts. They allow you to run up to 35-inch tires with proper lift and trimming. The process involves cutting the factory fender metal and bolting on the flat panels. This guide walks you through everything you need to know.
Jeep Cherokee Xj Flat Fender Flares
Flat fender flares are not just about looks. They provide critical clearance for larger tires during articulation. The factory flares limit tire size to around 31 inches without rubbing. With flat flares, you can fit 33s or 35s easily.
These flares are made from steel, aluminum, or fiberglass. Steel is durable but heavy. Aluminum is lighter and resists rust. Fiberglass is affordable but can crack. Choose based on your budget and wheeling style.
Benefits Of Flat Fender Flares
- Increased tire clearance for off-road performance
- Aggressive, minimalist appearance
- Reduced weight compared to stock flares
- Better airflow to brakes and suspension
- Easier to clean mud and debris
Tools And Materials Needed
Before starting, gather these items. You will need a grinder with cutting wheels, a drill with metal bits, rivet gun, measuring tape, marker, and safety gear. Also get the flat fender flare kit, primer, and paint if needed.
- Angle grinder with 4.5-inch cutting disc
- Drill and 1/8-inch pilot bit
- Rivet gun and 1/4-inch rivets
- Marker or chalk for layout
- Safety glasses and gloves
- Flat fender flare kit (steel or aluminum)
- Rust-inhibiting primer and spray paint
Step-By-Step Installation Guide
1. Remove The Factory Flares And Trim
Start by taking off the stock plastic flares. They are held by screws and push clips. Pry them off carefully. You will see the factory fender metal underneath. Mark the cutting line about 1.5 inches above the factory lip. This gives you room for the flat flare.
Use the grinder to cut along the line. Cut slowly to avoid overheating the metal. Wear a mask to avoid inhaling dust. After cutting, smooth the edges with a file. Clean the area with degreaser.
2. Test Fit The Flat Flares
Place the flat fender flare against the cut edge. It should sit flush. Adjust the cut if needed. Most kits come with predrilled holes. Mark these holes on the fender using a marker. Drill pilot holes at each mark. Use a center punch to prevent the bit from wandering.
Check alignment from front to back. The flare should follow the wheel well curve. If it does not, trim the flare or fender slightly. Patience here prevents gaps later.
3. Apply Primer And Paint
Remove the flare and prep the bare metal. Apply rust-inhibiting primer to the cut edge and drilled holes. Let it dry per instructions. Then spray paint to match your XJ’s color or leave it black for contrast. Many people prefer black for a rugged look.
Paint the flares separately if you want a custom color. Let them cure for 24 hours before installing.
4. Bolt Or Rivet The Flares
Position the flare back on the fender. Insert rivets or bolts through the holes. Tighten evenly from center outward. Do not overtighten or you may warp the metal. Use washers to distribute pressure.
For steel flares, you can weld them instead of riveting. Welding gives a cleaner look but requires skill. Riveting is easier for DIYers and allows removal later.
5. Seal And Finish
Apply silicone sealant along the top edge of the flare. This prevents water and mud from getting behind it. Smooth the sealant with a finger. Let it dry for a few hours. Check all fasteners are tight.
Test the clearance by turning the wheels fully. Cycle the suspension up and down. If you hear rubbing, trim more metal or adjust bump stops.
Choosing The Right Flat Fender Flare Kit
Not all kits are the same. Some are universal and require cutting. Others are model-specific for the XJ. Look for kits that include mounting hardware and instructions. Popular brands include Rugged Ridge, Smittybilt, and DIY flat stock.
- Rugged Ridge: Steel, heavy-duty, black powder coat
- Smittybilt: Aluminum, lighter, corrosion resistant
- DIY flat stock: Custom cut to your spec, weld or rivet
Consider the width of the flare. Wider flares cover more tire but look more aggressive. Narrow flares are subtler. Measure your tire width and offset before ordering. A 4-inch wide flare works for most 33-inch tires.
Common Mistakes To Avoid
Many first-timers cut too much metal. Start with a conservative cut and test fit. You can always cut more but cannot add metal back. Also, do not skip primer and paint. Bare metal rusts quickly, especially off-road.
Another mistake is using cheap rivets. Use stainless steel or aluminum rivets for durability. Plastic rivets break easily. Also, ensure the flare is level with the body line. A crooked flare looks unprofessional.
Do not forget to adjust your bump stops. Larger tires need more clearance. Install extended bump stops to prevent tire contact at full compression.
Maintenance Tips For Flat Fender Flares
Flat fenders collect mud and rocks. Clean them after every off-road trip. Use a pressure washer to remove debris. Check rivets and bolts for looseness. Tighten as needed. If you painted them, touch up chips to prevent rust.
Inspect the sealant annually. Reapply if it cracks or peels. This keeps moisture out of the fender well. With proper care, flat flares last for years.
Performance Impact
Flat fender flares reduce weight by several pounds per corner. This improves acceleration and braking slightly. More importantly, they allow larger tires that increase ground clearance and traction. Your XJ will climb rocks and cross ruts better.
The trade-off is more dirt and mud thrown onto the body. Without the factory flares, the sides get dirty faster. Consider adding mud flaps if you drive on roads. Some states require them for tire coverage.
Cost Breakdown
Flat fender flare kits cost between $100 and $400. DIY flat stock is cheaper but requires more work. Professional installation adds $200 to $500. Paint and primer cost $30 to $60. Total investment is around $200 to $800 depending on your choices.
Compare this to custom fiberglass fenders that cost $600 to $1000. Flat flares are the budget-friendly option for serious off-roaders.
Frequently Asked Questions
Do flat fender flares require cutting the fender?
Yes, you must cut the factory fender metal to install flat flares. The cut removes the inner lip and allows the flare to sit flush. This gives you the extra clearance.
Can I install flat fender flares without welding?
Absolutely. Most kits use rivets or bolts. Welding is optional for a cleaner look. Riveting is strong enough for off-road use if you use quality hardware.
Will flat fender flares fit 35-inch tires on a Jeep Cherokee XJ?
Yes, with proper lift and trimming. You need at least 4-5 inches of lift and bump stop extensions. Flat flares provide the clearance for 35s without rubbing.
Are flat fender flares street legal?
It depends on your state laws. Some require tires to be covered by fenders. Flat flares may not cover wide tires fully. Check local regulations before installing.
How long does installation take?
Expect 4 to 8 hours for a first-time install. This includes cutting, test fitting, painting, and mounting. Experienced mechanics can do it in 2 to 3 hours.
Final Thoughts
Flat fender flares transform your Jeep Cherokee XJ into a capable off-road machine. They are practical, affordable, and easy to install. With the right kit and careful work, you can fit bigger tires and improve performance. Follow the steps above and enjoy your upgraded XJ.
Remember to take your time with the cutting and alignment. Rushing leads to mistakes. Measure twice, cut once. Your XJ will thank you on the trail.