How to Install Bushwacker Fender Flares

Installing Bushwacker fender flares is a fantastic way to upgrade your vehicle’s look and protect your paint from debris. This guide provides a simple, step-by-step walkthrough to ensure a professional finish. Whether you are prepping for off-road adventures or just want a custom look, we have you covered.

So, you finally decided to beef up your rig. You’ve probably spent a lot of time scrolling through photos of lifted trucks and customized SUVs, and you know what caught your eye: those wide, aggressive fender flares. Bushwacker is the gold standard in the industry. They are tough, they look amazing, and they serve a real purpose by covering wider tires and protecting your body from flying rocks.

But then you look at the instruction manual and see words like “drill,” “template,” and “torque.” It can feel a little intimidating. Don’t worry! You don’t need to be a master mechanic to get this done. If you can use a screwdriver and a drill, you can definitely handle this project. In this guide, I am going to walk you through the process just like I would if we were working on my truck in my own driveway.

Before we jump into the heavy lifting, remember that this is a project of patience. You want those flares to look factory-installed, not like they were slapped on in a rush. If you are currently preparing your Jeep Wrangler for off roading, adding these flares is one of the best next steps you can take to protect your vehicle from the elements.

Key Takeaways

• Preparation is Key: Always clean your vehicle and gather all necessary tools before starting.
• Template Usage: Use the provided templates to ensure perfect alignment and spacing.

li>Drilling Precision: Take your time when drilling holes to avoid cracking the factory plastic or metal.

• Hardware Tightness: Tighten bolts in a star pattern to ensure even pressure across the flare.
• Protect Your Paint: Using masking tape can prevent scratches during the installation process.

Gathering Your Tools and Supplies

Before you even touch a bolt, you need to make sure you have everything on hand. There is nothing worse than being halfway through drilling into your fender and realizing you left the drill bit in the garage. It breaks your momentum and can lead to mistakes.

Essential Tool List

You are going to need a few basics. First, a power drill with a set of high-quality drill bits. You will also need a socket wrench set, specifically small metric or standard sizes depending on your vehicle. A screwdriver (both Phillips and flathead) is a must. I also highly recommend having a tape measure, a permanent marker, and some painter’s tape handy.

Cleaning Supplies

You cannot install flares over a layer of dirt or wax. If you do, the seal won’t be tight, and you might end up with rattles or even leaks. Grab some soap, water, and a microfiber towel. You want that fender surface to be as clean and smooth as possible before the plastic meets the metal.

Pre-Installation Prep and Marking

This is the most important stage of the entire process. If you mess up the measurements here, the flares will look crooked, and you might have to redo the drilling. This is where “measure twice, cut once” really applies.

Using the Template

Most Bushwacker kits come with a paper template. This is your best friend. Tape the template onto your fender exactly where the flare is intended to sit. Once it is taped down, double-check the alignment. Does it look centered? Does it align with the existing wheel well shape? If it looks off, move it before you mark anything.

Marking Your Holes

Once the template is perfectly positioned, use a marker to trace the holes through the paper. I recommend using a fine-tip permanent marker. After you have marked the holes, carefully peel the paper template away. Now, you should see small dots on your vehicle’s fender. These dots are your roadmap for the drill.

Protecting the Vehicle

A pro tip that I use every single time: apply a layer of painter’s tape over the area where you will be drilling. This prevents the drill bit from “walking” (sliding across the surface) and, more importantly, it prevents the paint from chipping when the bit breaks through. It is a small step that saves a lot of headache later.

The Drilling Process

Now we get to the part that makes most people nervous: the drilling. It is okay to be nervous, but just remember to go slow. You are drilling into plastic or metal, and you want to be steady.

Selecting the Right Bit

Check your kit for the recommended drill bit size. If you aren’t sure, it is better to use a slightly smaller bit and then enlarge it if needed. If you use a bit that is too large right away, you might end up with a hole that is too big for your hardware, which is a nightmare to fix.

Drilling Technique

Start the drill at a very low speed. This helps the bit “bite” into the surface without slipping. Once you have a small indentation, you can increase the speed slightly. Hold the drill perfectly perpendicular to the fender. If you tilt the drill, you will end up with an angled hole, and your bolts won’t sit flush against the flare.

Dealing with Metal vs. Plastic

If you are drilling into a metal fender, it will require more pressure and a slower speed. If you are drilling into a plastic fender flare mounting area, it will be much easier, but be careful not to apply too much pressure, or you might crack the plastic. Take your time and let the tool do the work.

Mounting the Fender Flares

Now that you have your holes, it is time for the actual installation. This is where the transformation happens! You will see your vehicle start to take on that rugged, wide-body look.

Positioning the Flare

Line up the holes in the Bushwacker flare with the holes you just drilled into the vehicle. It is often helpful to have a friend hold the flare in place while you start the first few bolts. This ensures the flare stays centered and doesn’t shift while you are working.

The “Star Pattern” Method

When tightening the bolts, do not just go in a circle. Instead, use a “star pattern” or a diagonal pattern. Start with one bolt, then go to the one directly opposite it, then move to the next one. This ensures that the pressure is distributed evenly across the entire flare. If you tighten one side all the way down first, the flare might sit crooked or even warp.

Checking for Gaps

After you have all the bolts in, take a look at the edges. You shouldn’t see any large gaps between the flare and the body of the vehicle. If you do, loosen the bolts slightly, reposition the flare, and tighten them again using the star pattern. You want a tight, snug fit to prevent wind noise or vibration while driving.

Post-Installation Inspection and Maintenance

You’re done! The flares are on, and the truck looks incredible. But the job isn’t quite finished until you’ve done a final check.

The Shake Test

Give the flares a firm tug or a gentle shake. They should not move at all. If they wiggle, you missed a bolt or didn’t tighten one enough. It is much easier to fix a loose bolt now than it is to fix a rattling fender while you are driving down a highway at 65 mph.

Cleaning and Protection

Since you just did all that work cleaning the car, keep it that way! Use a UV protectant spray on the Bushwacker plastic. These flares are designed to withstand the elements, but a little extra protection will keep them from fading in the sun over time. This is especially important if you live in a sunny area.

Regular Checks

After your first few trips, especially if you take your vehicle off-roading, check the bolts again. Vibrations from bumpy roads can sometimes cause hardware to settle or loosen slightly. A quick check with a wrench every few months will ensure your installation stays secure for years to come.

Common Troubleshooting Tips

Even with the best preparation, things don’t always go perfectly. Here are a few things you might encounter and how to handle them.

“My holes are too big!”

If you accidentally drilled a hole that is slightly larger than the bolt, don’t panic. You can buy “oversized” fender washers or use specialized plastic expanding rivets to fill the gap. It is much better than having to replace the entire fender panel.

“The flare is vibrating.”

If you hear a humming or vibrating sound, it is likely because the flare isn’t making full contact with the body. You might need to add some automotive-grade foam tape or “butyl tape” behind the flare to act as a buffer and dampen the vibration. This is a common trick used by professionals.

“The color doesn’t match perfectly.”

Keep in mind that aftermarket plastic can sometimes have a slightly different sheen than your factory paint. This is normal. Most people find that the aggressive look of the flares makes the color difference negligible, but it is something to be aware of.

If you find that your vehicle needs more than just cosmetic upgrades, you might be looking at mechanical changes. For example, if you are wondering how much to install coilovers to help support those wider tires, you’ll find that the cost varies depending on the brand and the complexity of the lift. But for most people, Bushwacker flares are the perfect “bang for your buck” modification.

In conclusion, installing Bushwacker fender flares is a rewarding DIY project. It requires a bit of precision and a steady hand, but the result is a vehicle that looks more capable and stays cleaner. Take your time, use the right tools, and enjoy the new look of your ride!

Frequently Asked Questions

Do I need to cut my fenders to install Bushwacker flares?

It depends on the specific model and the type of flare. Some Bushwacker kits are “bolt-on” and only require drilling, while others may require cutting the factory plastic fender liner or even a small portion of the metal fender if you are running much larger tires.

Will fender flares make my car louder?

If installed correctly, they should not make any noise. However, if they are not tightened properly or if there is a gap between the flare and the body, you might experience wind whistling or vibration at high speeds.

Can I install these myself without professional tools?

Yes, you can do this with basic hand tools like a drill, sockets, and a screwdriver. However, having a drill and a set of quality bits makes the process much easier and reduces the risk of error.

Are Bushwacker flares durable for off-roading?

Absolutely. Bushwacker is famous for creating high-quality, heavy-duty flares specifically designed to withstand harsh off-road conditions, including rocks, mud, and extreme weather.

Will fender flares require me to change my tire size?

Not necessarily. Many people install them purely for aesthetics. However, they are most commonly used when upgrading to wider or larger tires to ensure that the tire tread remains covered and doesn’t spray debris into the air.

How do I prevent my new flares from fading?

The best way to prevent UV fading is to apply a high-quality UV protectant specifically designed for plastics. Regularly washing your vehicle and keeping the flares free of harsh chemicals