Z-Max Fender Flare Instructions


Trust us on this one… before welding, we recommend removing your battery terminals, as well as the bench portion of your back seat.

29. Use a hammer to bend and shape the inner fender, giving your tire more clearance. Make sure the edge of the inner fender meets the new edge of the outer fender, so that you can weld the two together.

IMG_9035 (2)30. DO NOT weld the entire edge of the inner fender to the outer fender—this will distort the body. Instead, weld two tacks on each “tab” of the inner fender, to attach it to the outer fender.

31. Use a grinding wheel to clean up any rough edges or parts of the metal “tabs” sticking out too far.

Exact Shaping (optional)

OK, now is the time to sand or Bondo the flares, if you want to get the most exact fit.

32. Use a sanding block or electric sander to gradually sand away the fiberglass on the flare, where needed.

Snapshot - 333. If you want to fill in a gap between the flare and the body, remove the Z-Max Fender Flare, and use masking tape to cover the body behind the part of the flare where you’re working. Make sure the tape follows the shape of the body exactly.

Snapshot - 434. Replace the flare, and have your buddy hold it in place (or use a couple nuts, but don’t over-tighten) while you fill in the gap with body filler. Hold in place until the filler is rigid (about 2 minutes, usually, but check the directions on the can), and the pull the flare away from the tape. The body filler should stick to the fiberglass on the flare, and pull away from the masking tape without much difficulty.

35. Sand any uneven spots on the body filler with a sanding block, to get a smooth surface and smooth edges. Remove the masking tape from the Jeep.

Once the shaping is done, we recommend you leave the flares off until they’re painted, but whenever it is you bolt them on, DO NOT over-tighten the nuts!

Sealing, Painting, and Mounting

Snapshot 4 (1-28-2013 4-55 PM)36. Use a waterproof caulking or metal filler (like USC all-metal©) to fill in any slits or gaps in the wheel wells. Allow to cure.


PART_135827213758937. Tape off and cover your vehicle, tires, shocks, springs, etc., leaving the edge of the fender exposed, but do not expose past the bolt holes for your Z-Max Fender Flares.


Snapshot - 138. Use a spray can of rubberized undercoating, and apply a layer on the edge of the fender, and the inside of the wheel well, to protect the metal from corrosion.

39. Before painting your Z-Max Fender Flares, sand the entire outside with 220-grit sandpaper, until the whole surface is a lighter, dull gray.

40. Paint or cover your Z-Max Fender Flares as you wish. Your buddy might have a crazy idea, but here at Notch Customs, we think matching it to your vehicle looks the best.

41. Mount your fender flares, using the rubber washers and nylon lock nuts included with your Z-Max Fender Flares (11mm wrench). Again, DO NOT over-tighten the nuts! As you tighten the nuts, try to spin the washer with your fingers. Once the washer is snug, and you cannot spin it by hand, the nylon locking nuts will hold securely. Over-tightening may warp your body, or break the bolt loose from the flare.

Now your Jeep should look about this awesome:Still (2) Still (38) Still (45) Still (12)

Sweet! Now send us YOUR photos!

Tell your buddy to get some pictures of you with your new Z-Max Fender Flares, and send them to us We want to see your build, and you may end up featured on our website!

Any comments or suggestions?

We’d love to keep improving our products

and instructions for future customers. Send us a message and let us know

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