Fenders won't align after front clip rebuild

[dgold_881]

Ok First I bought this bronco with the front totally gone except for the hood original fenders and the front core support. I purchased new inner fenders sides ect. After taking several measurements from my other broncos I proceeded to weld the front clip back on. Now when I put the fenders on the front doesn't lay down along the inner side pieces except back by the door. I don't see how it can be off due to the front core supports are on the body mounts and measure correctly square to the front firewall. If I force the fender down the fender bows out back by the door looking like a prerunner fender? What is srewed up? I'm at a loss since the measurements are correct and the front core support is correctly mounted on the front body mounts. see Pictures attached. Any ideas would help thanks

 

[Rustytruck]

I believe the front core support is parallel to the firewall but not centered on the body. Its made off center just dont remember how much. this has be brought up in several very old posts. Do diagonal measurements with your other Broncos.

 

[dgold_881]

Yes I got that but the issue is with the fenders not laying down correctly? That gap shouldn't be there but the core support can't be lifted. I can't figure out why the gap is even there.

 

[CraigS]

Front frame twist?

 

[dgold_881]

I thought that to but the gap is on both sides evenly. So don't think the frame is bent.

Front frame twist?

 

[CraigS]

Don't shoot me but what about the mounts? Same size on the core support as the main body?

 

[JSmall]

Don't shoot me but what about the mounts? Same size on the core support as the main body?

I was thinking that too

 

[DaveLev]

Do fender holes and grill line up? What part exactly are out of whack...the fender holes and the inner fender holes?

 

[dgold_881]

Yes body mounts have the same mounts all the way around.

Don't shoot me but what about the mounts? Same size on the core support as the main body?

 

[dgold_881]

Holes line up just for some reason towards the bottom theres almost an inch gap from completely laying flat on the inner fender. And if I force it down causes the bottom rear of the fender to bow out.

Do fender holes and grill line up? What part exactly are out of whack...the fender holes and the inner fender holes?

 

[NGABronco]

Have you tried another fender??? Maybe a NOS type??;D;D;D

 

[AZ73]

It's difficult for me to see from the pictures, but I had somewhat of a similar problem. It turned out that the inner lip of the fender was spot welded incorrectly to the actual fender. I had to drill out all the spot welds, then line the fender up with the body lines of the door (using a string all the way back to the tail lights). Then I set the inner lip on the apron and used self tapping screws to hold it in place. Then pulled the fender off and welded them back together. However my fender was even with the grill and the gap was with the inner lip and the apron. On yours it might be the back part of the fender the inner lip is welded too low, but I can't see your body lines to judge if it's the fender or the apron. Post a picture of the new fender from the outside so we can see the body line.

 

[Tonka7777]

Can you post pics of the core support mounts, where they attach to the wheel wells?

 

[DaveLev]

Hmmm...the bolt holes on my fender lined up to grill and lined up to top of the inner fender, but the holes from inner fender to fender didn't come close. I know what you mean about the gap and if you force it it will bow the fender out. Almost sounds like the front clip is pointing downward, as was suggested. In addition to the core support mounts, what about a body lift or spacers or something wrong with the back 6 supports that might tilt the vehicle at an oddball angle I wonder. Hmmm.

 

[dgold_881]

Ok the photos I uploaded are side shots. The orange side with fender is with it forced down and the black fender is with it just laying in position with out being bolted with the gap. The body mount photo is of the front and cab mounts after the firewall. I also took a shot of the front core support bracket mounts from the top. When I installed the side apron to the front core support it went exactly where the old one was since I had to drill out the old weld and remove the left over piece that the guy left when he sawed it off?

It's difficult for me to see from the pictures, but I had somewhat of a similar problem. It turned out that the inner lip of the fender was spot welded incorrectly to the actual fender. I had to drill out all the spot welds, then line the fender up with the body lines of the door (using a string all the way back to the tail lights). Then I set the inner lip on the apron and used self tapping screws to hold it in place. Then pulled the fender off and welded them back together. However my fender was even with the grill and the gap was with the inner lip and the apron. On yours it might be the back part of the fender the inner lip is welded too low, but I can't see your body lines to judge if it's the fender or the apron. Post a picture of the new fender from the outside so we can see the body line.

 

[CraigS]

Since the inners are welded already can you lift the core support an inch to line up? I know you said you couldn't, but why not?

 

[dgold_881]

The apron wraps over the core support on the top there would be no way to do that. Even if I added a spacer to the front body mount the front clip is a solid 1 piece welded to the firewall by the aprons which are a perfect fit at that point. Its the slope down towards the front core support where the gap comes into play? But even then the front is welded correctly to the core support that's why this baffles me so much. Even tried new fenders and the same out come.

Since the inners are welded already can you lift the core support an inch to line up? I know you said you couldn't, but why not?

 

[Timmy390]

This tread is causing me SO much anxiety. I have a fender being delivered today.

Tim

 

[dgold_881]

Tell me about it

This tread is causing me SO much anxiety. I have a fender being delivered today.

Tim

 

[Timmy390]

Who's fenders are those? Not trying to call anyone out.......

Mine just got here and no damage in transit but it appears as if like said below,

It's difficult for me to see from the pictures, but I had somewhat of a similar problem. It turned out that the inner lip of the fender was spot welded incorrectly to the actual fender.

I'm judging this off the OEM fender that's on my rig now (it's cut and dented so i'm replacing it) compared to the new one I just got. The inner fender gaps are different and the welding job is CRAP so it should be easy to remove and adjust if needed.

In your pic it looks like the gap is very small but as said, hard to tell.

BTW, I bought my fenders from Dennis Carpenter due to the fact it was the same price as all the vendors but the shipping was a flat rate $14.99 vs the $80 plus everywhere else. They arrived in an "Oval Industries, Orange California" box.

I'll try to start working on getting the old off and new on tonight but I have a full plate....

Tim