88 YJ-CJ Rear Wheel Wells, Part 1

Now that the hole in the floor is substantially done, I'm continuing the metalwork on the rest of the tub:

Rear Wheel Wells, Part 1

The previous owner installed Jeep TJ rear fender flares, and they were still on the YJ when I purchased it.  

TJ rear flares are actually a good, common modification for YJs, as they are cost-effective and add a lot of tire clearance.  One downside is that you have to cut sheet metal to install them.  

I even had them on my 95 YJ for about 6 months back in 2014 before I went to tube fenders.

To get closer to a CJ7 look, I want to go with the round CJ7 rear flares.  

TJ Flare removed:

CJ Flare clamped in place...and the missing sheet metal is clearly noticeable.  

I made a cardboard template to help me think things through.  Ultimately, I'm not sure that it was very helpful.  But I might find it more useful later in the process.  

The wheel well lip was also cut off, and that gives a lot of strength to the sheet metal around the flare.  I decided to go ahead and recreate the lip too, which is some amount of work.  

I am limited by the size of my steel and my tools, so I am working with shorter pieces.  I'll have to fit in 6 separate pieces to re-create the correct wheel well with lip.  You can see the general plan in the picture below.

This is not ideal, but I can work with it.  It will just lead to more welding and more fitting.

I did a similar repair to my Jeepster fender a few years ago - the previous owner had cut some sheet metal for tire clearance.  So this process is not new to me.  

I started by cutting up 1.5" wide strips.  

Ready to be bent in the sheet metal brake - 1/2" is showing - that will be the new wheel well lip

After bending:

The "Stretcher" tool is the main one needed - it will put the curve into the part.

Unfortunately, it only has a 1" throat depth, so that limits my stock size.  (A "deep throat stretcher" is available, but too expensive -$400) 

Starting the stretch to make the curve.  I put black Sharpie marks every 1" as reference marks.  

Curve taking shape:

Curve done:

The curved ends took some time:

2nd piece about halfway done:

3 of 4 pieces done:

Passenger side - all 4 pieces done:

Driver's side - 1 of 4 done:

This will take a while - there will probably be 4 separate posts just on these wheel wells.