Fender Flares (High-Clearance Steel)
Brawler Lite, Comp Cut, and Bushwacker flares replace stock plastic. High-clearance steel flares trim the wheel well opening up to fit 33s and 35s with less lift.
Stock XJ fender flares are plastic and limit tire clearance to ~31". Going to 33s or 35s typically requires either (a) more lift, or (b) cutting and replacing the fenders. High-clearance steel flares (sometimes called "Brawler Lite" or "Comp Cut" style) are designed for option (b).
Process: cut the stock metal fender at the wheel arch, raising the lower edge by 1"-3". This exposes the inner wheelwell. The steel flare bolts on to cover the cut edge and provide a finished look. Result: more tire clearance with the same lift height, OR fitting bigger tires without going to extreme lift.
Good options:
- JCR Offroad Crusader steel flares: ~$420 (front), ~$340 (rear).
- Iron Rock Off Road Comp Cut flares: ~$380.
- Bushwacker pocket-style flares (plastic, broader coverage but limited cut): ~$280.
- DIY: $80 in 1/8" plate from a fab shop with templates.
Process overview:
- Mark cut line per flare manufacturer's template.
- Cut with cutoff wheel or plasma cutter.
- Grind smooth, treat with rust converter.
- Bolt or rivet on the steel flare.
- Paint to match (or leave bare with rust converter for a rugged look).
This is a one-way modification — you can't put the cut metal back. Plan tire size carefully before cutting. Most builders cut to fit 33s on 3.5" lift or 35s on 5" lift.
Downside: insurance/inspection in some states may flag cut fenders. Verify locally.
Why it works
- Fit larger tires with less lift
- Less leverage on suspension
- Improved approach/departure angles
Trade-offs
- Irreversible modification
- Rust mitigation required
- May affect inspection in some states
- Labor intensive
Tools required
- cutoff wheel
- grinder
- drill
- rivet gun or welder
- paint supplies
Parts
| Part | Vendor | Est. price |
|---|---|---|
| JCR Offroad Crusader steel flares (set of 4) | JCR Offroad | ~$700 |
| IRO Comp Cut flares (set of 4) | Iron Rock Off Road | ~$650 |
| Bushwacker pocket-style flares | Bushwacker | ~$280 |
Sources
Related
Written and maintained by an AZ wheeler and driveway wrencher. How we source guides. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.