Bushwacker Body Gear 40919-02 Fender Flare Installation

Bushwacker Body Gear 40919-02 Fender Flare Installation
Set Part # 40919
88-98 Chevy / GMC Pickup
Suburban / GMC 92-99
2DR Tahoe / Yukon 95-99
11-01-05 Rev-C
STEP 1.
Prior to Installation:
A) Fit: Verify you have ordered the right flares for your vehicle make
and model and check their fit.
B) Painting :( Optional) if paint is desired it must be done prior to
installing flares on the vehicle, clean outer surface with a good
grade degreaser. DO NOT USE LACQUER THINNER OR
ENAMEL REDUCER AS A DEGREASER. Wipe outer surface
thoroughly with a tack rag prior to paint.
Paint flares using a high quality enamel, or polyurethane
automotive paint. (Application of a primer coat is optional)
If painting edge trim (not recommended) use a flex additive.
C) Performance: Using larger Tires may increase the area
require to turn the vehicle. Some Tire/Rim combinations may
required lowering bump stops and or installing steering stops to
prevent tire from contacting flare.
D) Exhaust System: Modifications may be necessary to
maintain a minimum 4” clearance between flares and exhaust
pipes. (Exhaust gases should not vent directly onto flares)
TOOLS FOR EASY INSTALLATION
• Utility Knife
• #2 Short Phillips Screwdriver
• Drill motor, 5/16 Bit
• ½ Wrench
• Marker
FLARE INSTALLATION PROCEDURES
STEP 2:
Preparing the Work Area (Front and Rear)
Remove factory fender trim and mud flaps (when installed).
STEP 3: Edge Trim Installation
(See Illustration #1)
A) Peel two to three inches of red vinyl backing away
from edge trim tape. Applying the adhesive side of
the edge trim to the inner side of the flare, affix the
edge trim to the top edge of the flare (the portion
that comes in contact with the side of the vehicle).
B) Press edge trim into place along the top edge of
the flare in one-foot increments, pulling red vinyl
backing free as you continue to work your way
around the top edge of the flare.
6710 N. CATLIN AVE. • PORTLAND, OR 97203 • 503-283-4335 • 1-800-234-8920 (USA AND CANADA) • FAX 503-283-3007
STEP 4: (Front and Rear Flare)
Stainless Steel Screw Installation
(See Illustration # 2)
A) Using the indents on backside of pockets in flare as a guide
drill a 5/16 hole.
NOTE: DRILL HOLES BEFORE PAINT.
B) Insert stainless steel screw and washer into front of flare,
secure with jam nut, using supplied Torx bit. (See
Illustration # 2
Illustration #2)
STEP 5: Preparing Front and Rear
Flare Installation
(See Illustration # 3)
A) Remove factory fender trim, front fender body side
molding and mud flaps
(When installed).
B) Trim body side molding rear (when installed) so flare fits
base sheet metal. Hold flare up to wheel well opening
and mark a line on body side molding where flare
overlaps.
C) Remove flare, mark cut line 1/4” beyond overlap line.
Use blow dryer to heat molding.
D) Slide 6” wide knife between the molding and body of
vehicle.
E) Carefully cut on marked line with a utility knife, using the
putty knife as a guard against the vehicle.
F) Sand molding to desired finished edge.
STEP 6: Front Flare Installation
(See Illustration # 4)
A) Hold flare in position with moderate pressure. Using the
holes in the flares as a guide, mark wheel well lip where
each hole is.
B) Remove flare and stick a black Mylar tab over each
marked location. Slide supplied clamps over each tab
location. (See Illustration #6)
C) Hold flare in position and line up the holes in flare to the
threaded holes in clamps. Starting with the two top
holes, start the supplied screws, but keep loose.
D) Ensuring the flare is properly located on fender, install
remaining screws. Applying moderate pressure to
outside surface of flare, tighten screws, beginning with
the two top locations and then the two bottom screws.
Cut Line
Flare Outline
Cut Line
Wheel Well Opening
Wheel Well Rim
Molding
Molding
Illustration # 3
STEP 7: Rear Flare Installation
(See Illustration #5)
Illustration # 4
A) Hold flare in position with moderate pressure. Using the
holes in the flares as a guide, mark wheel well lip where
each hole is.
B) Remove flare and stick a black Mylar tab over each
marked location. Slide supplied clamps over each tab
location. (See Illustration #6)
C) Hold flare in position and line up the holes in flare to the
threaded holes in clamps. Starting with the two corner
holes, start the supplied screws but keep loose.
D) Insuring the flare is properly located on fender, install
remaining screws. Applying moderate pressure to
outside surface of flare, tighten screws, beginning with
the two corner locations and then the two bottom
screws. Tighten the top center screw last.
Illustration # 5
Flare
Fender
Mylar tab
Clamp
#10 Sheet
Metal screw
Illustration # 6
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