Cutting Flares, what did you use?

[needabronco]

I'm ready to cut my fenders out for Warflares, and I'm wondering what is the best/preffered method to cut the fenders? I've heard people using everything from a sawzall, cut off wheel, to a plasma cutter... I'm doing a frame off, so I'd like the cut edge to look as uniform as possible. Thanks for the help...

 

[22213evl]

cut off wheel.

 

[Oatmeal]

I'm a sheetmetal worker so, using aviation snips is second nature to me and provides the cleanest, most controled cut. Are you cutting into an uncut Bronco or just enlarging an already cut open fender? Use the cutoff wheel, like the other poster suggested, to get the rough opening and then do a clean trim with snips........that's how I would do it, anyway --------Hans

 

[LEDCREATIONS]

i used a cut off wheel. Prob the easy and clean way to do it.

 

[Explorer]

Body saw, nibbler both work well. But a plain old jig saw will get the job done.

 

[barronj]

I used a jig saw, and with good bits, it was a breeze. I taped up the bottom of the saw pretty well to avoid damaging the paint (it was getting repainted, but I didn't want extra work) with a few layers of duct tape.

A pilot hole to begin, and it was off to the races.

 

[JohnT]

Measure twice cut once , But plain ol jig saw worked great . Just be sure to where eye protection .

 

[blakerj10]

I like a 4.5 inch angle grinder with a cut off wheel.

 

[67broncorebuild]

I would stay away from air shears. It will ripple around the cuts (not much, but you can see it).

 

[JIMS74]

I used a cut off wheel. I drilled the holes and mounted the flare to the qtr panel before cutting it, then used a 3/4" wide straight edge to trace the cut line on the inside edge of the drilled holes to give a uniform 3/4" lip.
Jim

 

[carmi]

I prefer the sawsall with a fine tooth blade. No sparks to burn the glass or surrounding paint, plus much less heat. If you use tape as a guide, it will also reduce the paint chipping. Make sure you keep the foot pressed against the side you are removing so you don't chip / dent the side that is staying.

 

[itsabronco]

Jig saw, new blade each cut for max performance. Dont be in a hurry and it will come out perfect. some light filing to smooth edges .

 

[AGShelby]

Cutting

I used a jigsaw for the 1st one - was very slow and awkward.

Used a cutoff wheel for the other three - took less than a minute to do each cut.

 

[phred]

a bosch jigsaw with variable speed and fine cut blades. Slow and easy and if you can get someone to help have them spray WD40 of another paint friendly lube on the blade to keep it cool and not hurt the paint.

 

[Nightmare Bronc]

I used a jig saw with a metal cutting blade of course. It turned out very nice. I drilled a few holes, enough to hold the flare on, and mounted it. Drew a line around it the took flare off and then held flare 3/4 below the line I had and then drew another to cut.

 

[bax]

cut off wheel is your friend.

 

[67Stallion]

I used a sawzal with fine tooth blade, worked good for me!

 

[bsaunder]

pneumatic body saw with a couple new blades; clean cut and woks like a knife through warm butter.
Mask the area so you don't scratch it and mark your cutting line on the tape.

 

[NicksTrix]

plasma all the way. takes about a minute a side. slight fluff on the edge with a disc & i'm ready to go onto next step.
it comes down to what you feel comfortable with and have to work with. previously we've done them with a zizz wheel.

 

[Devin]

Jigsaw with a metal blade. Just like butter.