How To: Fiberglass fenders 97-03 bodystyle
How To: Fiberglass fenders 97-03 bodystyle
So you have this:
To do this you will need:
1. Flat head screwdriver
2. Phillips head screwdrive
3. 8mm socket
4. Socket extension
5. A putty knife or something else flat like that
6. Four bolts about 1.5" long with a nut and 4 washers
7. A dremel or a small cutting tool like this
8. Other small sockets for removing the rubber wheel wells (not sure of size)
9. BOLT BREAKER!!
10. Time, Patience, Dip, Cigarettes, etc. If this applies to you haha
Steps:
1. Disconnect the negative battery cable. Better safe then sorry haha
2. Remove the bumper, its 4 bolts along the frame rail, there big you can't miss them ha. On mine I didn't need to remove it because I have a prerunner bumper already but on a stock one you will need too.
3. Remove the tire jack bar and the rubber over the top of the grill. Use a phillips head to unscrew the bolts and a flat head to pop the little plastic parts out if they won't come out.
4. Pop the headlights free by pulling up and out on the headlight brackets and then unplug the headlights. Slip the flathead under the plugs clips and just pull them back. Then unbolt the corner lights, its a tiny socket needed and the bolt is located above the the corner light.
5. Then the grill is next. Unscrew all the phillips head screws along the top, and then the two behind where the corner lights were. Finally pull out and down to get the metal clips out below it. If the pop off the grill its okay, just push them back on the grill once its off.
6. Then remove the fender wells, theres about 4 bolts that require a tiny socket along the wheel well, two plastic snaps in the front below the corner light (I just cut these off) and then remove any other plastic trim by the rocker panels.
7. Its finally time to start unbolting the fenders.
There is two 8mm bolts behind where the corner lights were.
One below that where the plastic snaps were for the rubber fender wells.
Three along the inside of the hood by the hood support.
One underneath the windshield wipers, to get this use the putty knife and pop out the little plastic cap beside the wiper. Then unscrew the screw with a phillips head. Now some say to remove the windshield wipers and completely pull the piece off. I didn't do this however, I just gently pulled the side up, used the socket extension and unbolted it.
Next remove the foam that is by where the door hinges are, just pull it and it'll come off. There is one bolt above and below the door hinge.
Finally, the last two bolts are located where the fender connects to the rocker panel. ONCE you have these out try to wiggle the fender there, if it still doesn't move take the dremel and go around the edge of the fender by the back bolt to break it free from the rocker panels.
8. Now the fun part, pulling the fender off. I would imagine this part would be much easier with two people haha. But pull out from the top and up and down to break it free, the pull out and back from the top and by the rocker. There is two little plastic nubs behind where the corner light assembly is that you have to get it off of. Just pull and it'll come free eventually. After I had it off I used the dremel to cut off those little nubs, you won't need them.
9. Now its time to put the new one on. Hang it in place and try to get it as forward as possible and lower the hood almost all the way to make sure it'll clear the hood. The better you get it now the less sanding you will have to do later. BUT remember these fenders are made in a mold meaning they will not be perfect so you will still have to trim to clearance the door properly. I had to trim where it meets the corner light area to get it to slide in properly and tuck closer.
Once you have a decent fit on it, you have two options mark where you think the bolts will go or grab some painters tape, tape it in place and drill it where it is. Use a drill bit bigger than the stock 8mm screws though, you DO NOT want to thread them into the fiberglass it will CRACK them! I drilled the bolts in place I found this easier because I was working by myself.
Where the two bolts where by the corner light these thread into the fenders not the actually supports. This is where those 4 bolts come into place. Drill holes big enough for them to slide through the fiberglass, make sure you put washers on, and thread the bolt just loosely on the other side. Don't tighten it just use this to help hold it in place.
After I did those two, I did the two by the rocker panel. The first time I drilled, I only was able to see half of the threading for the bolt to go into so don't be afraid to miss, the 8mm bolts have washers on them so if you have to expand the hole some its okay! Once I had these two in I tightened them down all the way.
Next I did the three along the hood, again don't worry if you have to expand the hole some.
Now this part is up to you, I didn't do the ones by the door hinge or the one by the windshield wiper because after my fenders sat in my dads garage for almost a year, the tabs had all but broken off. So I left these three out, and I drove down the interstate doing about 75 and had no vibration from it so I'm not too worried.
Also don't forget the one thats below the corner light.
Now go back and tighten up all the bolts! And you should now have one in place, GET EXCITED cause the next side is easier once you get the first outta the way haha.
10. If your doing the passenger side you have to remove the antenna, to do this unscrew the antenna. Then use the putty knife again around the antenna bases cover to pop it free. Unscrew the three phillips head bolts and pull up and then unplug it. If you wanna remount it, you'll have to get three bolts with nuts and washers and drill a spot for it in the new fender, REMEMBER you don't wanna thread into the fiberglass. I left mine off though, I use my ipod all the time instead of the radio ha.
REPLACING THE RUBBER WHEEL WELL GAURDS
1. I held my old ones up to the new opening and made a rough mark of how far they needed to be cut. Then I took them back out and cut them all the way across, remember leave a little overhang you can always take off more, but you can't add!
Make sure you dont cut off the part where those two little plastic parts clip in either.
I then put it back up, and popped the two little plastic parts back in to hold. And starting from the front about every 6 inches I used a self tapping sheet metal screw to go threw the rubber and then into the core support.
Finally, go back and trim off the excess overhang you left.
2. Where the air intake is i used part of the original that I cut off first and screwed it in to cover it up.
3. Repeat this process for the other side but I didn't worry about step 2 cause theres no air intake over there haha.
MAKE SURE YOU CAN OPEN YOUR DOORS ALL THE WAY
My doors still wouldnt open without rubbing the fenders so now is the time to break out the dremel and start trimming along the fender till the door will open completely, same with along where the hood closes.
NOW PUT EVERYTHING BACK TOGETHER AND BE HAPPY WITH YOUR NEW FENDERS!!!!!!!!!!!
I'll put pictures up to go along with it either tuesday or wednesday when I go back and finish sanding haha
To do this you will need:
1. Flat head screwdriver
2. Phillips head screwdrive
3. 8mm socket
4. Socket extension
5. A putty knife or something else flat like that
6. Four bolts about 1.5" long with a nut and 4 washers
7. A dremel or a small cutting tool like this
8. Other small sockets for removing the rubber wheel wells (not sure of size)
9. BOLT BREAKER!!
10. Time, Patience, Dip, Cigarettes, etc. If this applies to you haha
Steps:
1. Disconnect the negative battery cable. Better safe then sorry haha
2. Remove the bumper, its 4 bolts along the frame rail, there big you can't miss them ha. On mine I didn't need to remove it because I have a prerunner bumper already but on a stock one you will need too.
3. Remove the tire jack bar and the rubber over the top of the grill. Use a phillips head to unscrew the bolts and a flat head to pop the little plastic parts out if they won't come out.
4. Pop the headlights free by pulling up and out on the headlight brackets and then unplug the headlights. Slip the flathead under the plugs clips and just pull them back. Then unbolt the corner lights, its a tiny socket needed and the bolt is located above the the corner light.
5. Then the grill is next. Unscrew all the phillips head screws along the top, and then the two behind where the corner lights were. Finally pull out and down to get the metal clips out below it. If the pop off the grill its okay, just push them back on the grill once its off.
6. Then remove the fender wells, theres about 4 bolts that require a tiny socket along the wheel well, two plastic snaps in the front below the corner light (I just cut these off) and then remove any other plastic trim by the rocker panels.
7. Its finally time to start unbolting the fenders.
There is two 8mm bolts behind where the corner lights were.
One below that where the plastic snaps were for the rubber fender wells.
Three along the inside of the hood by the hood support.
One underneath the windshield wipers, to get this use the putty knife and pop out the little plastic cap beside the wiper. Then unscrew the screw with a phillips head. Now some say to remove the windshield wipers and completely pull the piece off. I didn't do this however, I just gently pulled the side up, used the socket extension and unbolted it.
Next remove the foam that is by where the door hinges are, just pull it and it'll come off. There is one bolt above and below the door hinge.
Finally, the last two bolts are located where the fender connects to the rocker panel. ONCE you have these out try to wiggle the fender there, if it still doesn't move take the dremel and go around the edge of the fender by the back bolt to break it free from the rocker panels.
8. Now the fun part, pulling the fender off. I would imagine this part would be much easier with two people haha. But pull out from the top and up and down to break it free, the pull out and back from the top and by the rocker. There is two little plastic nubs behind where the corner light assembly is that you have to get it off of. Just pull and it'll come free eventually. After I had it off I used the dremel to cut off those little nubs, you won't need them.
9. Now its time to put the new one on. Hang it in place and try to get it as forward as possible and lower the hood almost all the way to make sure it'll clear the hood. The better you get it now the less sanding you will have to do later. BUT remember these fenders are made in a mold meaning they will not be perfect so you will still have to trim to clearance the door properly. I had to trim where it meets the corner light area to get it to slide in properly and tuck closer.
Once you have a decent fit on it, you have two options mark where you think the bolts will go or grab some painters tape, tape it in place and drill it where it is. Use a drill bit bigger than the stock 8mm screws though, you DO NOT want to thread them into the fiberglass it will CRACK them! I drilled the bolts in place I found this easier because I was working by myself.
Where the two bolts where by the corner light these thread into the fenders not the actually supports. This is where those 4 bolts come into place. Drill holes big enough for them to slide through the fiberglass, make sure you put washers on, and thread the bolt just loosely on the other side. Don't tighten it just use this to help hold it in place.
After I did those two, I did the two by the rocker panel. The first time I drilled, I only was able to see half of the threading for the bolt to go into so don't be afraid to miss, the 8mm bolts have washers on them so if you have to expand the hole some its okay! Once I had these two in I tightened them down all the way.
Next I did the three along the hood, again don't worry if you have to expand the hole some.
Now this part is up to you, I didn't do the ones by the door hinge or the one by the windshield wiper because after my fenders sat in my dads garage for almost a year, the tabs had all but broken off. So I left these three out, and I drove down the interstate doing about 75 and had no vibration from it so I'm not too worried.
Also don't forget the one thats below the corner light.
Now go back and tighten up all the bolts! And you should now have one in place, GET EXCITED cause the next side is easier once you get the first outta the way haha.
10. If your doing the passenger side you have to remove the antenna, to do this unscrew the antenna. Then use the putty knife again around the antenna bases cover to pop it free. Unscrew the three phillips head bolts and pull up and then unplug it. If you wanna remount it, you'll have to get three bolts with nuts and washers and drill a spot for it in the new fender, REMEMBER you don't wanna thread into the fiberglass. I left mine off though, I use my ipod all the time instead of the radio ha.
REPLACING THE RUBBER WHEEL WELL GAURDS
1. I held my old ones up to the new opening and made a rough mark of how far they needed to be cut. Then I took them back out and cut them all the way across, remember leave a little overhang you can always take off more, but you can't add!
Make sure you dont cut off the part where those two little plastic parts clip in either.
I then put it back up, and popped the two little plastic parts back in to hold. And starting from the front about every 6 inches I used a self tapping sheet metal screw to go threw the rubber and then into the core support.
Finally, go back and trim off the excess overhang you left.
2. Where the air intake is i used part of the original that I cut off first and screwed it in to cover it up.
3. Repeat this process for the other side but I didn't worry about step 2 cause theres no air intake over there haha.
MAKE SURE YOU CAN OPEN YOUR DOORS ALL THE WAY
My doors still wouldnt open without rubbing the fenders so now is the time to break out the dremel and start trimming along the fender till the door will open completely, same with along where the hood closes.
NOW PUT EVERYTHING BACK TOGETHER AND BE HAPPY WITH YOUR NEW FENDERS!!!!!!!!!!!
I'll put pictures up to go along with it either tuesday or wednesday when I go back and finish sanding haha
Last edited by pizzaman711; Apr 14, 2011 at 11:32 AM.
Senior Member
Joined: Dec 2006
Posts: 1,226
Likes: 0
From: Walnut Creek,Ca
Great write up. Few questions-
Did you use the same self-tapping sheet metal screws to go through the fiberglass when you attached the inner fender part by the intake?
Did you pre drill the holes?
Roughly how long do you think it took?
Did you use the same self-tapping sheet metal screws to go through the fiberglass when you attached the inner fender part by the intake?
Did you pre drill the holes?
Roughly how long do you think it took?
Time wise working by myself it probably took about 16 hours including sanding to get the doors right, but once I had one side done it made the second a lot easier.
And yea I just drilled everything in place I found it easier to do it that way.
Senior Member
Joined: Jul 2007
Posts: 3,291
Likes: 0
From: Beaverton Or.
Looks good. Nice that you found a way to fab your splash guards back into place. Some people who have the fiberglass fenders did not reuse the splash guards and have issues with water. And it looks much better than having to look at the side of the engine.
Yea I was worried about the engine so I made sure I did something to cover it up and your right it looks ten times better haha.
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ha thanks man, my girlfriend saw your truck the other day and today she was like "you need to get the camo on your truck like the red f150 its cute haha", she loves your truck ha