Mud Flap install with DIY shortened Rock Rails on a First Edition Bronco

[BlueBoy]

Installed a set of the frugal ($49 a pair vs $900 Gatorbacks) OEM mud flaps on my Lightning Blue FE. Not wanting to cut the triangle hole in the front flaps for the rock rails, I opted to shorten the rails 2 inches on each side. I started by removing each rail which was pretty straightforward (6 nuts and 3 bolts per side).

Since there isn't a reasonably priced solution, I trimmed the cheaper set until Rokblokz releases their products. First I held the flap against the extended fender flairs and marked them by dragging a scratch awl along the outline. Once marked I used a sharp utility knife and steady hand to cut the rubber (not confident w/ Dremel and it cut fast). I used the included bolts/clips to attach.

With the rails off, I removed the front endcaps which are secured with a torx screw and plastic push fastener. I determined that cutting 2" from the leading edge would give enough clearance for the mud flaps while still giving adequate rock rail protection. Using a protractor, I determined two angles of 10 degrees need to be cut using a compound miter saw. I have a 14" cutoff saw which is fixed at 90degrees so I opted for the compound miter saw. They dont make a 12" cutoff wheel so I took a chance and used an old carbide tipped blade to make the cuts. In order to make the cuts, I flipped the rail upside down and had to elevate the saw so the rock rail brackets wouldn't be touching the ground and interfering with the cuts. I let the blade do the work with slight pressure and it made great cuts. Then deburred the inside/outside if the rail w/ a file. Using the cut pieces, I laid them on the new leading edge and with a 90degree pick, marked the holes to drill new holes for the torx and push fasteners. I finished it off w/ satin black paint for the cut edges. Prior to reinstalling, I taped off the pinch weld edge, scuffed with fine steel wool and coated with black rubberized undercoating

Next up will be the install of removable steps which are halfway done.
Link to initial rear mud flap install:
https://www.bronco6g.com/forum/thre...-sasquatch-with-side-steps.30544/post-1033099

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[SpeedTwin]

Nice work. How did you trim the rears to fit?

 

[BlueBoy]

Nice work. How did you trim the rears to fit?

I removed the Sasquatch end caps from the rear bumper and laid them over the rear flaps to trim them to fit

 

[Bongo Fury]

FE BRNCO
very nice tag

 

[BlueBoy]

FE BRNCO
very nice tag

Thx, had to order in January of '20 to snag it

 

[Mustang_75_99]

@BlueBoy How did the mud flaps attach to the wheel well? I want to get some, but I am curious how the OEM mud flaps will impact the fender flares and the fender flare removal.

 

[BlueBoy]

@BlueBoy How did the mud flaps attach to the wheel well? I want to get some, but I am curious how the OEM mud flaps will impact the fender flares and the fender flare removal.

The mud flaps do not impact the removal of the rear Fender flares wahtsoever. However, the front flares have a small hole drilled in them with a Christmas tree black push pin to hold the mud flap to the bottom edge of the the flare

 

[78fordf150]

Thanks for this write up on trimming the rock rails down. Your success at using the miter saw has given me enough confidence in my abilities that I'm gonna try it on mine. I have a 12in Dewalt double compound sliding saw that should be up to the task.
Thanks

 

[BlueBoy]

Thanks for this write up on trimming the rock rails down. Your success at using the miter saw has given me enough confidence in my abilities that I'm gonna try it on mine. I have a 12in Dewalt double compound sliding saw that should be up to the task.
Thanks

Sure thing. Was leery at first cutting on a new vehicle but one the angles were figured out, it went a lot smoother

 

[Denny3297]

I am replying for 2 reasons:

1. Thanks for being a pioneer and figuring this out! Kudos to you
2. I am hopeful my Badlands will be here soon, and this will be one of the first things I do. I need to be able to find this post easily in the future.

 

[BlueBoy]

I am replying for 2 reasons:

1. Thanks for being a pioneer and figuring this out! Kudos to you
2. I am hopeful my Badlands will be here soon, and this will be one of the first things I do. I need to be able to find this post easily in the future.

Np. Funny thing is the Mrs asked why I am posting on B6G. Had to explain that I have gotten so much from everyone else's exploits and not reinventing the wheel, I should be giving back when I can. BtW, you picked a sweet trim for a Bronco. That was my #1 choice had I not got lucky w/ an FE.

 

[Firefight911]

Thanks for this. I used this thread as a template to handle the modification of a set of rails I just acquired from another forum member through the marketplace. They are being installed on my wife's Base Bronco.
Instead of using a compound miter saw, I used an angle grinder. After removing the end caps, I cleaned up and wrapped the rails with painter's tape approximately 2-1/2" from the end to be cut. Once I did this, I measured and marked the entire circumference with a line for my reference while cutting. Used some C-clamps and clamped the rails to my workbench and then cut the rails using the marked line. Once done, a little cleanup and then some paint after carrying over the new holes and drilling them. Replace the caps and the screws and push-button holders. Piece of cake.
Thanks again! Ran out of time to install them today. Should be able to get them installed within the next day or two, schedule allowing.

 

[BlueBoy]

Thanks for this. I used this thread as a template to handle the modification of a set of rails I just acquired from another forum member through the marketplace. They are being installed on my wife's Base Bronco.
Instead of using a compound miter saw, I used an angle grinder. After removing the end caps, I cleaned up and wrapped the rails with painter's tape approximately 2-1/2" from the end to be cut. Once I did this, I measured and marked the entire circumference with a line for my reference while cutting. Used some C-clamps and clamped the rails to my workbench and then cut the rails using the marked line. Once done, a little cleanup and then some paint after carrying over the new holes and drilling them. Replace the caps and the screws and push-button holders. Piece of cake.
Thanks again! Ran out of time to install them today. Should be able to get them installed within the next day or two, schedule allowing.

Great work, include a couple pics when you get them installed

 

[Firefight911]

Here ya go…

 

[BlueBoy]

Here ya go…

Sweet, very clean install! IMHO, I think the shortened rail has a cleaner look then the triangle cut through the flaps. I like your steelies too

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