Hey CCOT, here are some instructions on converting FJ40 fenders over to BJ40 fenders for all those Canadian Cruiserheads. Most of the differences are in the passenger side fender. The bracket on the top/inside of the fender has to be removed, I removed just the very inside of this bracket so I could get the battery tray in. The piece on the upper part of the fender doesn't have to be removed, but then again it's directly underneath the air filter in-feed, so it's not much use for anything. To remove the bracket I first cut it in half with a cutting wheel, then the drilled out the spot welds, I didn't drill all the way through the fender, only the bracket material. I then made some backing plates for the diesel air cleaner, the factory fenders had these backing plates so I copied them and then pre mounted the air cleaner on the upper part of the fender. Once I marked the locations of the holes, I removed the fender and drilled the upper holes. Bolted the air cleaner in place and marked and drilled the lower holes. Both sets of holes have backing plates, I had to work around the two pre-mounted nuts for the upper fender skirt. I also made up some re-inforcement plates for the bottom of the fenders where the running boards mount. I then spot welded all of the backing plates into place. To prevent water/rust for getting in-between any of the spot welded pieces I used Zero Rust paint. I thinned the paint down a bit so it would flow in-between the pieces of metals for the first two coats, I then painted it a few more times. The drivers side fender required only the bottom backing plate for the running boards, and that's optional. Basically no big differences between the FJ40 and BJ40 fenders, I'm sure you could just remove that one bracket and drill a few holes and be off to the races. |
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