Installing Bushwacker fender flares can enhance the aesthetic and functional aspects of a vehicle, particularly in off-road or rugged environments. These flares are designed to provide additional coverage for tires, protect against damage from debris, and complement aftermarket bumpers. However, the installation process varies depending on the specific style of flares—such as OE, Street, Pocket, or Cut Out. This guide provides a comprehensive overview of the installation steps, supported by specifications, tools, and practical considerations from multiple sources. The instructions are intended for U.S. users and are based on detailed, verified information from official installation guides and user experiences.
Understanding Bushwacker Fender Flare Styles and Specifications
Bushwacker offers several fender flare styles, each with unique installation requirements and design features. The following specifications and features were documented across multiple sources:
OE (Original Equipment) Style Fender Flares: These flares are designed to closely resemble factory-installed components. They are typically secured using the same methods as Street Style flares, including drill tip screws and adhesive edge trim.
Street Style Fender Flares: These are the most common type and are generally easier to install. They also use drill tip screws and require adhesive edge trim to prevent contact with the vehicle's paint.
Pocket Style Fender Flares: These are more involved to install, often requiring the removal of existing factory flares, fender trim, and mud flaps. The process includes trimming the inner fender liner, drilling, and reassembling the components.
Cut Out Fender Flares: These require the most labor, as they involve cutting into the fender to create a custom fit. This is often the most time-consuming option and is typically recommended for those with advanced mechanical skills or professional installation.
A set of Front and Rear OE or Street Style flares may provide tire coverage of 1.25 inches, with a height of 4.50 inches. These flares are compatible with aftermarket bumpers, both front and rear. The price for a complete set of these flares is approximately $510.
Preparing for Installation
Before beginning the installation, it is essential to gather the necessary tools and materials. The following items are typically required:
- Jack and jack stands: To safely lift and support the vehicle during installation.
- Drill and bits: A 5/16” bit is commonly used to remove rivets, and an 11/32” socket may be needed for installing LED turn signals.
- Trim tools and pry tools: These are essential for removing factory flares without damaging the vehicle's body or paint.
- Adhesive edge trim: This is provided with the flare kit and must be applied to the inner edge of the flare to prevent contact with the vehicle’s paint.
- Push clips and drill tip screws: These are included in the hardware pack and are used to secure the flares to the inner fender well.
It is also recommended to thoroughly clean the fender wells before beginning the installation. This ensures that the adhesive on the edge trim adheres properly and that the flares fit correctly without interference from dirt or debris.
Step-by-Step Installation Instructions
1. Removal of Existing Components
Before installing new Bushwacker flares, it is necessary to remove any existing fender flares, trim, or mud flaps. This process may vary depending on the age and model of the vehicle. For example, some factory flares are secured using plastic rivets that must be removed with a drill and 5/16” bit. Others may use push clips, which can be removed with a trim tool or flathead screwdriver.
In one reported installation, the user encountered difficulty in removing stubborn factory flares. A set of plastic trim pry tools was ultimately used to avoid damaging the vehicle's paint. Users are advised to exercise caution during this step to prevent accidental damage to the vehicle’s body or surrounding components.
2. Preparing the Fender Flares
Once the factory components have been removed, the new Bushwacker flares can be prepared for installation. The adhesive edge trim should be applied to the inner edge of the flare. This is done by peeling back the red backing strip a few inches at a time and pressing the adhesive side firmly against the flare. This step is crucial to prevent the flare from rubbing against the vehicle’s paint, which could cause damage over time.
Some users reported that it was easier to apply the edge trim before installing the flares, especially for Pocket or Cut Out styles. This method allows for better control and ensures full adhesion before the flares are secured in place.
3. Installing the Flares
The installation process varies slightly depending on the flare style:
Street and OE Style Flares: These are typically the easiest to install. After applying the adhesive edge trim, the flares are placed in the fender well and secured using the provided drill tip screws. The flares are marked with indentations that indicate the exact locations for screw placement.
Pocket Style Flares: These require trimming the inner fender liner to accommodate the flare. The user must cut the sheet metal along the marked lines, drill through spot welds, and bend the metal edges outward to remove the liner. The flares are then reinstalled using a combination of factory 10mm bolts and new push clips provided in the hardware pack.
Cut Out Flares: These are the most complex to install. The process involves cutting into the fender to create a custom fit. This requires precision measurements and careful cutting to ensure the flare aligns correctly with the wheel and fender. The adhesive edge trim is applied after the flare is cut and trimmed, and the flares are then secured using drill tip screws and push clips.
4. Reinstalling the Fender Liners
After the flares are installed, the fender liners must be reinstalled. This step is particularly important for Pocket Style flares, as the liner must be trimmed and adjusted to fit around the new flare. The front fender liner is typically tucked behind the sheet metal and secured with a push clip, while the rear fender liner is installed using the same hardware as the original components.
In some cases, the wiring for the front turn signals may need to be adjusted. If the new LED signals are not aligned with the original wiring, the user may need to cut the old plug, strip the wires, and attach heat shrink bullet connectors. It is important to verify the polarity of the LED signals, as incorrect connections can lead to malfunction or permanent damage.
5. Final Checks and Adjustments
Once all components are installed, it is essential to inspect the flares and hardware for proper alignment and fit. The user should ensure that the adhesive edge trim is fully adhered and that the flares do not rub against the vehicle’s paint. If any adjustments are needed, they should be made before the vehicle is lowered from the jack stands.
Some users noted that the screw holes on the inner pieces did not always align perfectly with the flare holes. In such cases, gentle force may be required to align the components, but care must be taken to avoid breaking the screw heads or damaging the flare material.
6. Tips for a Successful Installation
- Work in a clean, well-lit area to avoid dirt buildup on the adhesive and to ensure clear visibility during installation.
- Double-check all measurements and markings before cutting or drilling to avoid costly mistakes.
- Use a helper when lifting and securing the flares, especially for larger or heavier models.
- Test the LED turn signals before finalizing the installation to ensure they function correctly.
- Take your time—haste can lead to errors, especially when working with precision components like fender flares.
Common Installation Challenges and Solutions
Several users reported challenges during the installation process, particularly with Pocket and Cut Out styles:
Difficulty in removing factory flares: Some users found that plastic tabs on factory flares were fragile and could be easily broken. A set of plastic trim pry tools was recommended to avoid damaging the vehicle’s paint.
Misaligned screw holes: In one case, the screw holes on the inner pieces did not line up with the flare holes. The user had to force the pieces into place or drill an additional hole to accommodate the flare.
Limited space for tools: Some users struggled with accessing the inner fender well due to tight spaces. Removing the wheel was necessary to allow room for the drill and other tools.
Broken screw heads: Several users reported that screw heads broke during installation, particularly when using excessive force to align components. This issue can be mitigated by using a higher-quality screwdriver and applying steady, even pressure.
Paint damage: Some users noted that prying on stubborn flares could cause minor paint damage. A gentle approach with pry tools and avoiding excessive force is recommended to preserve the vehicle’s appearance.
Conclusion
Installing Bushwacker fender flares can significantly enhance the aesthetic and functional performance of a vehicle. While the process varies depending on the flare style, it generally involves removing factory components, applying adhesive edge trim, and securing the new flares with drill tip screws and push clips. Users should be prepared to invest time and effort, particularly for Pocket and Cut Out styles, which may require cutting, trimming, and reassembling components. By following the step-by-step instructions and heeding practical tips, users can achieve a professional-looking installation that enhances both the appearance and durability of their vehicle.