Fender Flare Connection Points Look Flimsy

[Portapot]

If and when I ever get my Bronco one thing I’ve been pondering is how fragile the fender flare connection points look. I have several places on my F250 with sheet metal like that, and they seem prone to rust quick. Anyone thinking of ways to give those areas some extra life proactively? I’m worried in three years they are rusted through and they will no longer hold the fenders securely. I guess permanent fender flare are always an option? Thoughts? As an example could we coat them with bed liner, my fear is that may mess up the way the flares seat themselves?

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[Beachin 74]

If and when I ever get my Bronco one thing I’ve been pondering is how fragile the fender flare connection points look. I have several places on my F250 with sheet metal like that, and they seem prone to rust quick. Anyone thinking of ways to give those areas some extra life proactively? I’m worried in three years they are rusted through and they will no longer hold the fenders securely. I guess permanent fender flare are always an option? Thoughts? As an example could we coat them with bed liner, my fear is that may mess up the way the flares seat themselves?

Aren't the fenders on the Bronco aluminum?

 

[Portapot]

Aren't the fenders on the Bronco aluminum?

Very good point, totally forgot about that. I guess that will help considerably.

 

[Theherofails]

Ive never even seen rust on a vehicle before... but 125f does funny things to plastic. We shall see. Ford does hot weather vehicle testing a few miles from my house. Never a good sign, is it?

 

[ATLBronco75]

Aluminum doesn’t rust.

 

[Wanted33]

Sadly I see quite a few Police reports for stolen Bronco fenders as soon as the crooks find out how easy they are to remove. Hopefully the aftermarket will come up with some type of locks, or something else to make it a bit more difficult to remove those things.

 

[Efthreeoh]

Aluminum doesn’t rust.

Well, "rust" is simply corrosion (oxidization) of iron-based metals. Aluminum does corrode too. Maybe some aftermarket will make stainless steel fenders.

I'm wondering how rust proof the Bronco frame will be and the best way to prevent it from rusting.

 

[Jdc]

Well, "rust" is simply corrosion (oxidization) of iron-based metals. Aluminum does corrode too. Maybe some aftermarket will make stainless steel fenders.

I'm wondering how rust proof the Bronco frame will be and the best way to prevent it from rusting.

Aluminum builds up an oxide layer that prevents further corrosion.

 

[Efthreeoh]

Aluminum builds up an oxide layer that prevents further corrosion.

True, but it depends on the alloy used, the environment it is used in, and the application of the part. It's not like aluminum is some magic material that gets surface corrosion and that's it; it still can fail due to corrosion.

 

[North7]

If and when I ever get my Bronco one thing I’ve been pondering is how fragile the fender flare connection points look. I have several places on my F250 with sheet metal like that, and they seem prone to rust quick. Anyone thinking of ways to give those areas some extra life proactively? I’m worried in three years they are rusted through and they will no longer hold the fenders securely. I guess permanent fender flare are always an option? Thoughts? As an example could we coat them with bed liner, my fear is that may mess up the way the flares seat themselves?

You are way over thinking this, you sound like a fellow aerospace engineer?

The flat, ribbed aluminum fender area, with the holes for the flares is at least 10 times the strength of the lightweight plastic flares. They are not going anywhere unless you leave the quarter turn fasteners unlocked.

Let us know what you find out after you run your model.
https://www.simscale.com/product/fea/

 

[BroncoT]

True, but it depends on the alloy used, the environment it is used in, and the application of the part. It's not like aluminum is some magic material that gets surface corrosion and that's it; it still can fail due to corrosion.

The only real concern is galvanic corrosion. Paint is an adequate buffer between steel and aluminum. Steel fasteners also can be plated or galvanized to help prevent corrosion between the two dissimilar metals. Both surfaces can and do break down under poor conditions. I rate It as a very minor risk though, but something I’ll check every few years or whenever it comes to mind.

over torquing and otherwise damaging the protective coating is the avoidable risk Bronco owners should consider

 

[Ecobeast]

Sadly I see quite a few Police reports for stolen Bronco fenders as soon as the crooks find out how easy they are to remove. Hopefully the aftermarket will come up with some type of locks, or something else to make it a bit more difficult to remove those things.

I’ve seen this reposted over and over and I think it’s kind of silly. The market for used fender flares isn’t going to be big enough for thieves to give a crap about these. You will get the oddball A-hole with a damaged fender flare on their bronco that will “borrow” yours but thieves won’t be targeting these.

It’s not like catalytic converters where they can scrap them for cash. They would need to sell them on eBay or something. Wouldn’t be worth anyone’s time.

 

[MattyAg]

The only real concern is galvanic corrosion. Paint is an adequate buffer between steel and aluminum. Steel fasteners also can be plated or galvanized to help prevent corrosion between the two dissimilar metals. Both surfaces can and do break down under poor conditions. I rate It as a very minor risk though, but something I’ll check every few years or whenever it comes to mind.

over torquing and otherwise damaging the protective coating is the avoidable risk Bronco owners should consider

It’s best to clean aluminum with mercury. Just a couple drops will do. Shines like brand new /s

 

[Deleted member 3063]

I'm wondering how rust proof the Bronco frame will be and the best way to prevent it from rusting.

as far as I know the Toyota Tundra and certain Jeep products are bench marks on what not to do.
in 40yrs of driving Ford trucks not one had any significant frame rust.

 

[wavydave]

It’s best to clean aluminum with mercury. Just a couple drops will do. Shines like brand new /s

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