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Thread: FJ fender bulge repair

  1. #11
    Forum Regular mk-Zero's Avatar
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    Re: FJ fender bulge repair

    Holy crap Mike, is that safe to drive? Looks like it could fail catastrophically.
    2010 FJ 4x4 AT: DeMello, All-Pro, Icon, RCI, BFG KM2, BajaRack, SpringTail.
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  2. #12
    Noob wheelinyotas's Avatar
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    Re: FJ fender bulge repair

    Quote Originally Posted by mk-Zero View Post
    Holy crap Mike, is that safe to drive? Looks like it could fail catastrophically.
    I don't really know. It's my daily driver and I only have one bandaid left until I understand what the fix entails!



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  3. #13
    Santiago Peak Tour Guide Sanderhawk's Avatar

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    Re: FJ fender bulge repair

    I`ve had cracks on both sides now for 11 yrs. They haven`t got any worse. They haven`t caused any problems. Its my DD and I still offroad it ll the time. Get them fixed if you want to but I wouldn`t worry about them to much. JMO

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  5. #14
    Noob wheelinyotas's Avatar
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    Re: FJ fender bulge repair

    I did a lot of combing the web, lots of issues with fender bulge and no good standard fix resolution. However, I did find some images of a fix on a older Blue FJ and a newer Yellow FJ that appear to have pretty sound logic. I'm thinking an combination of the two examples shown would yield that fix results desired. Does anyone have first hand experience doing a similar repair to their rig?







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  6. #15
    Forum Regular Irving Zisman's Avatar
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    Re: FJ fender bulge repair

    That looks pretty straight forward to me. Bend it back in place and weld some plate steel over the tear.

  7. #16
    Forum Regular siick motorsports's Avatar
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    Re: FJ fender bulge repair

    Quote Originally Posted by cruiser47 View Post
    Wow! Yours is the worst I've seen.
    Toyota did reinforce this area but I don't know what model year they started.
    Will removal of the fender gain access?

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    10-14 years

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  8. #17
    Forum Regular badgas's Avatar

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    Re: FJ fender bulge repair

    Quote Originally Posted by wheelinyotas View Post
    Can you (or someone) send me photo of 2010 & up FJ inner fender. Curious what visual difference Toyota did to reinforce this same problem area.


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    This is what a stock 2011 looks like


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    Forum Regular Fjforles's Avatar
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    Re: FJ fender bulge repair

    2010 fj

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  10. #19
    Beyond Help CptnStinkFinger's Avatar

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    Re: FJ fender bulge repair

    I have welded up a couple of these, ran a bead along the edge for good measure. Driver's side only so I blame the added mass of the group 31M battery, and some less than gentle landings.

    Quote Originally Posted by Fjforles View Post
    2010 fj

  11. #20
    Forum Regular JeppaCrzy's Avatar
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    Re: FJ fender bulge repair

    2012 driver side

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    2012 TT: BajaDesigns Squadron Pro in grille | Uniden CB w/ 4' Firestick on CH5 | ST Fuse Block

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