Jeep Cherokee XJ Rear Fender Stretch

A guide on how to cut, extend, and rebuild the rear quarter fender and wheel well in a Jeep Cherokee to gain more clearance.
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DISCLAIMER: Due to factors out of the control of Muddy Beards 4X4, we cannot guarantee against improper use or unauthorized modifications of this information. Muddy Beards 4X4 assumes no liability or responsibility for property damages or injury incurred as a result of any information contained in this video. Use this information at your own risk. Muddy Beards 4X4 recommends safe practices when working on vehicles and/or with tools seen in this video. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Muddy Beards 4X4. Be safe! This video and description contains affiliate links, which means that if you click on one of the product links, we receive a small commission. This helps support the channel and allows us to continue to make videos like this. Thank you for the support!

[@maewer1177]

Great job. I really like this kind of content . I enjoy seeing fabrication a lot more than just bolting parts on.

[@MuddyBeards4X4]

Well thanks. We enjoy building things ourselves. Thanks for watching

[@brettmoore1306]

Well done dude. Just got another xj and found some rust at rear wheel well and plan to do this exact thing

[@bdalton0295]

I’m about to embark on replacing rusted out leaf spring pockets under the seat along with the cargo area floor and I have a fairly clean parts jeep that I can cut plenty of sheet metal from. This video has now given me quite a few other ideas to do at the same time and this will let me move the axle back a tad too. I might even go all the way back to the fuel door.

[@mallen8164]

For bending the metal I used my old truck and the yard. Put the plate in the grass and drive on it. Curves the steel nicely and you can bend it back if you go to far. Learned the hard way resurfacing a plow blade. Good job on the build.

[@danielvalentin6852]

A little trick from the mini truck scene, cut and use a trailer fender, fill in back section and bam done

[@bemyers123]

I like your thought process. You put a fair amount of effort into this project.

[@MuddyBeards4X4]

Thanks man. It was no easy task.

[@TheAmericanUhate]

Been wanting to do this to my 2 door XJ for a while now. Definitely a great video, thanks

[@MuddyBeards4X4]

Thanks man! I would like to see it done on a two door

[@bennycurrin1593]

you are a brave dude!!

[@johnnyfrazier9864]

Man I loved this video who ever cut the fenders on mine before I bought it cut the seam and filled it with great stuff I was thinking of doing something like this but was contemplating due to lacking of ideas thanks for the great video and ideas keep up the good work

[@MuddyBeards4X4]

Thanks man. I appreciate it and good luck with the project

[@braxtonbowring]

Best xj video I’ve seen so far great content 👌🏻

[@MuddyBeards4X4]

Thanks man. Appreciate it.

[@jake-mv5oi]

Nice work. Gonna be doing this on mine to stuff some 39.5s under it.

[@MuddyBeards4X4]

Thanks man. I wish I was running that size tire.

[@2S1L3NT]

Fu**n awesome! I was just removing my factory flares after I added the lift and tires, and first drive down the road the front tire ripped the driver side front flare off 🤣 When looking at the back I didn't like how small the opening looked compared to the front. Researching- I realized that pinch seam was structural and you can't just cut it and leave it be. I think I'm gonna attempt this! My only fear is having to weld that sheet metal. I don't know if my welder can dial down enough for it. Awesome job, that looks perfect!

[@MuddyBeards4X4]

.023 wire and turn settings way down. It was a pain for sure. Sheet metal sucks to work with in my opinion

[@2S1L3NT]

@@MuddyBeards4X4 haven't tried wire that small yet, I'll give it a shot. Thank you!

[@kurtjensen7930]

That was a well though out !!!! Looks like it’s going to do the job

[@jeremyhanna3852]

I did something similar a few yrs ago I'm running 35' on 3" lift and home built rear four link

[@phillipmoore7283]

wow this is incredible. Very clean final product!

[@MuddyBeards4X4]

Thanks man. Appreciate the compliment

[@TheBeardedJeeper]

wow that turned out great! love the fabrication I need to do more of this

[@MuddyBeards4X4]

Thanks man. It was a lot of work but totally worth it.

[@shannonkelley5146]

That was a sweet project. Thank you for sharing.

[@GoatOffroad]

I would be so nervous to cut my Jeep! However, I think I have plenty of clearance for my baby 31’s. 🐞IIII🐞( nice Stepbrothers quote ) Lol

[@MuddyBeards4X4]

But this way there is room to upgrade.

[@erichughes9098]

Thanks for the video 😎👍

[@NoNaSRT4]

Unbelievable! Thanks! Make more videos.. giving me alot of great ideas!!!

[@MuddyBeards4X4]

Thanks man. I appreciate it.

[@s10buddy]

Like it a lot. Had the same sore of idea for a future project of my own.

[@shanepowell5115]

Danm Dude GREAT IDEA AND LOOKS AWESOME and in only 23 minutes (Wink, Wink) Shane P.

[@MuddyBeards4X4]

Oh it was a lot of work in 23 mins lol

[@saltymethods2637]

Nice work! Keep up the good work.

[@jeffsmodifications5965]

Nice job I have a similar problem but looks like I have to do some repair to the rear inside bed also as mine is a 1995 cherokee any help greatly appreciated idears for doing this

[@danhambrick6331]

Nice fab work....

[@05glisedan]

Maybe you've covered this. What leaf springs are you running? I'm looking to get around 2" stretch back... Great video. Thanks for sharing.

[@MuddyBeards4X4]

The leafs are i believe 3.5 inch rubricon express.

[@officialWWM]

My wife came out to the garage and saw me hacking my Jeep up with a grinder and nearly had heart failure 😂😂

[@DrHavok1]

Nice job man

[@MuddyBeards4X4]

Thanks brother

[@autotek7930]

Whoever had my xj in the past cut the pinch weld off both sides in the rear. Still trying to figure out how ima fix that. Best I've come up with is clean up the cuts and pinch it together and weld it but I dummy see that going to well coz of how bad it is

[@thomascollins9214]

That looks great. Why did you only cut off 4 inches in the rear? I think it looks awesome just wondering.

[@MuddyBeards4X4]

Thomas if I went back any further I would have had to relocate the fuel hoses. I didn't want to go that extreme. If this doesn't work I'll prob cut more

[@ChasWG]

Interesting video man! Very clever solution! Thanks for doing it. I'm about to cut into my rear 1/4 panels myself. I'm not running nearly as large of a tire as 36's, but more clearance is always an issue. This video really helps me by showing me the anatomy of the XJ before I dig into it. One question though, are you thinking about plating up the frame rails at all? I did the mid frame stiffeners on my 95 XJ and I was shocked how nice that made the XJ feel. Very solid. The front probably wants the entire front axle removed to do it properly and the rear needs the gas tank removed to full access back there I suppose. Again, thanks for the video man!

[@MuddyBeards4X4]

Thanks man! Glad the video helped. Yes I have reinforced the un in the mid section only so far. I actually just made my own out of some angle iron. I plan on making my own in the front and possibly rear too. It's certainly worth it to stiffen the unibody, especially if you offroad.

[@ChasWG]

Edit: Never mind. I just found and watched your video on plating the frame rails.

[@xbmarc]

So much more room for activities!!! Lol.

[@lordrudimus]

Good stuff

[@scottnicholson463]

You may not answer since this vid is so old. Are you using a 110 welder or 220? I have a 110 so I was curious if it was strong enough. Should be since it's sheet metal

[@MuddyBeards4X4]

Sheet metal work w Either would be fine. I was using my Hobart 190 (220 volt) but turned way down with .023 wire

[@erickphipps5931]

Are you running stock motor? I have 33’s and it’s not to peppy given the fact it has 200000 miles

[@MuddyBeards4X4]

Ya stock motor. However I have 4.56 gears so it does ok. Gearing is the best replacement for lack of power.

[@erickphipps5931]

Awesome thanks for getting back

[@MuddyBeards4X4]

No problem brother. Thanks for watching

[@rsvp6]

How many hours did it take on the first one? It looks great by the way.

[@MuddyBeards4X4]

A long time. I had never done it before so it was all trial by fire. I would say easy 10 hours. But other side went quicker

[@D0njuandelanooch]

Hey! Idk if you still check this channel, but I need to replace the rear quarter on my xj because the part where the flares and the body meet has completely rusted out. Is it plausible to just buy a rear quarter and weld it in or should I do a rebuild of the well like this?

[@MuddyBeards4X4]

I dont think you can buy a quarter. The body is pretty much all one piece. Maybe you could cut one off another rig and weld it in? I would just rebuild it though probably less work and less body work

[@D0njuandelanooch]

@@MuddyBeards4X4 that may be the route I take I plan on hiding it behind some body armor anyway. I really appreciate the response!

[@rickiloftis553]

What kind of seam sealer did you use? And how has it held up since then?

[@MuddyBeards4X4]

Its just automotive seam sealer I think I got at auro zone, and so far so good. I actually popped one of the spot welds when bolting on quarter panel armor and the sealer was still holding on. I had to grind it all off to reweld it.

[@kofabandadventures8900]

What did you do to clear the tires in the front?

[@MuddyBeards4X4]

A lot of cutting lol. I still have some issues with clearance so I might try to figure out something up front too

[@kofabandadventures8900]

@@MuddyBeards4X4 I have 33s and when I flex and turn aft the same time I rub. I had to replumb my snorkel with pvc cause the tire rip it out.

[@MuddyBeards4X4]

Dang man. How much lift? You might have to bump stop it.

[@kofabandadventures8900]

@@MuddyBeards4X4 4inch lift but I did the fender cut and the cut and fold in the rear. I want to do a lcog build. Around 6inch and 37s to 40s. Was wondering how to make room. Might have to strech it.

[@jeefcherky6699]

What axles are you running with the 36’s? Love the cut, my front and rear rub was going to bump stop front and cut the rear... now i know how I’m cutting the rear! (;

[@MuddyBeards4X4]

Right on man. It's totally worth it. I have no more clearance issues. I'm running the stock 30 up front and a Ford 8.8 in the rear.

[@jeefcherky6699]

Muddy Beards 4X4 cool!! Any better axle shafts in the front? I still have the Chrysler 8.25. Did you go from 35 to 8.8?

[@MuddyBeards4X4]

Nope stock shafts. No issue yet.....but I'm sure the time will come. And yes it had a 35 and swapped to an 8.8

[@jeefcherky6699]

Muddy Beards 4X4 I’ve ripped apart 2 front shafts lol going through fordyce this last year. Have 1 tons but haven’t built them yet. Waiting for another 1k and time for the 4.6 stroker. Not sure if I need it. So many plans, so little time ...

[@MuddyBeards4X4]

I hear that man lol. Also too little budget.....

[@1amazingdad854]

Which side of the pinch seam did you cut?

[@MuddyBeards4X4]

I cut just to the outside of the seam leaving the lip on the inner fender

[@ekbanjosworld4926]

Why don't you just cut ALL of the fenders off and get 40" tires? 🙄

[@suchasreallife]

Just leave it fender less itll be like a Comanche

[@MuddyBeards4X4]

Lol. I suppose that's an option but with it being a unibody i would want to run it that way.