AJ's Offroad Armor :: Quarter Panel Cut And Fold

Quarter Panel Cut And Fold

Quarter Panel Cut And Fold

The rear quarter panels on a Cherokee are not only prone to damage from obstacles encountered offroad, but rust as well due to their design. A popular modification that is necessary for use on our Tanker Rear Bumpers. It doesn't require any specialized tools or welders, this has been done by beginners with great success. As with anything, feel free to contact us with any questions or concerns you may have!

 

Here is the start of things, which is drawing out where to cut on the actual panel. NOTE: the red line is where you cut all the way around the panel. The blue line is where to cut a little later on.

Here is what it will look like when you have cut all the way around...

The next step is to cut where that blue line was in the first pic, which results in this...NOTE: You cut like this on the inner part of the fender as well!
The Blue arrow show how that peice will fold up later. The peice that will show after cutting is outlined in purple, and has the red arrow pointed towards it. This peice folds up flat on the inside of the quarter panel.

This is a picture of the inner part of the fender when cut.the peice outlined in blue is what will fold up, to situate where the red box is. The lighter blue outline of the folding up peice is actually how much should be cut on the inner part. I cut a little bit too much, but it still worked out.

Cherokee cut and fold

This is a picture of that inner peice outlined in purple before being folded up flat to the inside.

cherokee cut and fold


The next two pictures are the metal starting to be folded up.

cherokee cut and fold

cherokee cut and fold

This is the metal all folded up, being sealed with some sealant before I start pop-riveting...

cherokee cut and fold

This is it sealed up and pop-riveted on the outside.

cherokee cut and fold

This is what it looks like from the top of the inside. Some of the pop rivets didn't want to cooperate so I had to make sure they were working from the inside.

cherokee cut and fold

Since some paint chips did come off in the process I repainted the area. I am sure it can be done without harming the paint, but I wasn't as subtle with it as I could have been.

cherokee cut and fold

This is the finished product, in the second picture you can look closely and see the pop rivets(sorry camera sucks).

cherokee cut and fold

Cherokee Cut and fold

All in all it took about an hour to do both sides. I would recommend doing the passenger side first, because which ever side gets done last looks better(practice). Getting this done I used an assortment of tools(dremel, angle grinder, BFH, 2x4 and floorjack, and pop riveting tool, etc.) I love how it looks, and it will be real functional on the trail.

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