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View Full Version : Fitting Flexi Flares to a 5 door d1!!


long stroke
9th August 2010, 07:45 PM
Hey all:)

Well i have resontly completed fitting a set of flexi flares to my disco1 5 door.
I thought i may as well do a bit of a tutorial while i'm at it to hopefully help other's out who also plan to fit these flares in the future;)

Anyhow, i found the instruction's in the fitting kit to be very vague:eek: so i just fitted them the most logical way to me...

Tools used-

# black marking pen
# 4'' angle grinder with 1mm cutting disc's and flapper/sander disc.
# masking tape
# electric drill
# 2mm drill bits (suggest you get hold of a few of these as i broke a couple:angel:)
# phillips style screw driver
# touch up paint and brush

Step1-

First off i held the flare in place about where i wanted it to sit (a second person would make this easyer) to get the correct hight i went off the dimple part in the guard as suggested in the instructions, then marked a line around the inside of the flare.

https://www.aulro.com/afvb/images/imported/2010/08/1064.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1065.jpg

Then i masked an area about 10mm above the marker line using masking tape..

https://www.aulro.com/afvb/images/imported/2010/08/1066.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1067.jpg

The masked edge is where the cut will be made to allow for plenty of adjustment for where you want the flare to sit.

Step2-

Now the fun part, out with the angle grinder and try cut along the edge of the tape line as neatly as possible:angel:

https://www.aulro.com/afvb/images/imported/2010/08/1068.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1069.jpg

all cut..

https://www.aulro.com/afvb/images/imported/2010/08/1070.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1071.jpg

Step3-

Trim the inner guard plastic back to sit inline with the cut on the panel..

https://www.aulro.com/afvb/images/imported/2010/08/1072.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1073.jpg

Step4-

Position the flare where you want it to sit...

https://www.aulro.com/afvb/images/imported/2010/08/1074.jpg

Then drill the holes in the flare for the screw to go through into the guard, i used a 3mm drill bit for this to make it easyer to get the screws through the flare. i then fitted the rubber stripping to the edge of the flare..

https://www.aulro.com/afvb/images/imported/2010/08/1075.jpg

once the flare is sitting in the best position possible, drill away:D

https://www.aulro.com/afvb/images/imported/2010/08/1076.jpg

Step5-

Screw the flare onto the gaurd using the screws and plastic cover caps provided in the kit:)

And it should look something like this hopefully..

https://www.aulro.com/afvb/images/imported/2010/08/1077.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1078.jpg

and thats one side done!!!:cool:

I would suggest trying to fit some sort of guard to provent mud getting in between the flare and the inner guard, i'm yet to do this..

Now on the other side front, i pretty much followed the exact same steps but to make it abit quicker i turned the piece of off-cut from the other side over and traced this:D

https://www.aulro.com/afvb/images/imported/2010/08/1079.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1080.jpg

All fitted as well..

https://www.aulro.com/afvb/images/imported/2010/08/1081.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1082.jpg


With the front all done it was time to start on the rear arches.

Step1-

Obviously these are a 2 piece flare so i started on the harder one first..the door flare.

hold in place with the top of the flare in line with the dimple in the body then trace a line along the inside of the flare.

https://www.aulro.com/afvb/images/imported/2010/08/1083.jpg

Then i masked in up..

https://www.aulro.com/afvb/images/imported/2010/08/1084.jpg

Step2-

now once again out with the grinder..

https://www.aulro.com/afvb/images/imported/2010/08/1085.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1086.jpg

You will soon learn that you will have to cut through two parts on the door and in my case i had to remove the door seal that sat in the way of my cut:D

https://www.aulro.com/afvb/images/imported/2010/08/1087.jpg

Step3-

Then i traced another line on the inside wheel well where the door seal use to seal against:angel:
Then cut away..

https://www.aulro.com/afvb/images/imported/2010/08/1088.jpg

It should then look something like this..

https://www.aulro.com/afvb/images/imported/2010/08/1089.jpg

Step4-

Because the door is mainly steel you will have to touch the cut edges up with some kind of paint to suit..

Cleaning the edges up..

https://www.aulro.com/afvb/images/imported/2010/08/1090.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1091.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1092.jpg

Touching up..

https://www.aulro.com/afvb/images/imported/2010/08/1093.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1094.jpg

Seeing there will now be a large gap in you door i would suggest trying to fill it in with some silicone or similar, i still have to do this also.

Step5-

Drill the holes in the flare, then position the flare where you want it to sit, drill the holes and screw it on:cool:

https://www.aulro.com/afvb/images/imported/2010/08/1095.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1096.jpg

I found with the rear flares they didn't realy sit correctly on the door/guard but once it is screwed on they seem to be fine:)

Now for the rear part of the rear flare.

Step1-

Hold in position, and trace a line using the inside part of the flare as a guide.

https://www.aulro.com/afvb/images/imported/2010/08/1097.jpg

Step6-

Tape it up, and start cutting.

https://www.aulro.com/afvb/images/imported/2010/08/1098.jpg

Seeing i have already cut away the rear quarters and fitted a rap around rearbar i had to trim and re-cap the ends of my bar:(

https://www.aulro.com/afvb/images/imported/2010/08/1099.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1100.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1101.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1102.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1103.jpg

all cut..

https://www.aulro.com/afvb/images/imported/2010/08/1104.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1105.jpg

Step7-

once holes are drilled into the flare, Hold in position and drill then screw:cool:

https://www.aulro.com/afvb/images/imported/2010/08/1106.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1107.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1108.jpg

Fitted..

https://www.aulro.com/afvb/images/imported/2010/08/1109.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1110.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1111.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1112.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1113.jpg

I have about an inch clearence on the front and back of the rear tyres when fully flexed up into the guard running 33/12.5/15'' tyres 0n -25 off-set rims..

https://www.aulro.com/afvb/images/imported/2010/08/1114.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1115.jpg

https://www.aulro.com/afvb/images/imported/2010/08/1116.jpg

On the other side rear i followed the same steps apart from using the off-cuts for templets to make it quicker and easyer:)


Hope this helps a few of you..

P.s i still have to trim the end off the rear flares to sit flush with the bar..

CHEERS TIM.
Matman
9th August 2010, 08:07 PM
Nice work Tim.Looks like it made a huge difference in clearance.So when are you coming over to do mine:p
dullbird
9th August 2010, 08:10 PM
well done Tim

I'm sure a lot of people will find this really really helpfull
SPROVER
10th August 2010, 07:38 PM
Great work Tim.Makes it alot easier for people like me who want to put there flares on and are a bit hesitant about doing it.Great write up and good pictures to suit.Thanks for that.
Cheers
Chris
lux201
11th August 2010, 08:14 AM
nice and tidy! when I did mine I simply placed jigsaw in one hand, pointed with finger on other hand, closed one eye, placed tongue on cheek and went for it..

for the gap in the rear door I used door rubber as I had some left over, it clipped onto the inner guard and filled the gap nicely. Also I had enough to run along the very inner guard where the door meets just to tidy things up.

i'll post a pic or 2 when I get back from work.
lux201
11th August 2010, 10:53 AM
nice and tidy! when I did mine I simply placed jigsaw in one hand, pointed with finger on other hand, closed one eye, placed tongue on cheek and went for it..

for the gap in the rear door I used door rubber as I had some left over, it clipped onto the inner guard and filled the gap nicely. Also I had enough to run along the very inner guard where the door meets just to tidy things up.

i'll post a pic or 2 when I get back from work.

pics: a bit rough but does the job.. main reason for the rubber where the door meets the body was to stop mud etc getting up there and it works a treat.

http://img690.imageshack.us/img690/7510/snc00001l.th.jpg (http://img690.imageshack.us/i/snc00001l.jpg/)
Uploaded with ImageShack.us (http://imageshack.us)
http://img294.imageshack.us/img294/1755/snc00002dh.th.jpg (http://img294.imageshack.us/i/snc00002dh.jpg/)
Uploaded with ImageShack.us (http://imageshack.us)
long stroke
11th August 2010, 07:41 PM
Thanks for the pics mate!!

Nice work, that sorts out that issue for me:)

CHEERS TIM.
Disco_owner
15th August 2010, 04:32 PM
excellent work tim. great tutorial. :)






do you wanna do mine?:angel::D
nigelbuilding1984
5th September 2010, 10:10 PM
great tutorial did mine today with no problems
got my flares sent over from mm 4x4 heaps cheaper than over here
Presto
27th September 2010, 09:41 PM
Awesome Tutorial Tim!

I'm just about to buy some 33's for my D1, so fitting flares is inevitable!
Where can I get some of these flares from? What is mm 4x4?

Any info appreciated!:)
hills boy
28th September 2010, 03:36 AM
Discovery Parts - Range Rover Accessories - Defender - Freelander - Land Rover Spares - OffRoad Parts, Off Road Equipment & Accessories (http://www.mm-4x4.com/index.asp)

MM-4X4 Is a company in the UK i think a few people on here have ordered stuff in the past, not me personally. They look like they have some good stuff tho.
dirtdawg
28th September 2010, 04:07 AM
are you running a body lift or just suspension i have 33's to fit to my disco and am wondering if they will fit with the 2 in lift that i have and cutting the guards as you have done?
long stroke
30th September 2010, 11:18 PM
Awesome Tutorial Tim!

I'm just about to buy some 33's for my D1, so fitting flares is inevitable!
Where can I get some of these flares from? What is mm 4x4?


Any info appreciated!:)

Thanks mate:)

Give us a call at Coffs Harbour 4wd Centre and have a talk with Ant or Marty we have a few sets in stock and it will save you having to export them from over sea's:D

Number: (02) 6653 1800



are you running a body lift or just suspension i have 33's to fit to my disco and am wondering if they will fit with the 2 in lift that i have and cutting the guards as you have done?

Hi Dirtdawg:)

no i'm not running a body lift, just a suspension lift, mine is about 4'' lift in the back and 3'' in the front without any rubbing.
It is possible to fit 33's under the guards of a d1 with only a 2'' lift and flexi flares, it is a pretty tight fit but does work.
I know Boxer on here fitted 285/75/16's (33's) on neg 25 rims without any issue's might be worth giving him a pm to find out a bit more about it:)

CHEERS TIM.
dirtdawg
1st October 2010, 07:51 AM
yeah im using standard disco steelies
Presto
1st October 2010, 08:24 AM
Thanks Tim! ;)
loanrangie
13th September 2013, 02:43 PM
So today i started marking out for cutting my guards ,fronts no problem but rears are awkward due to the rubber bumper strip not allowing the flare to sit flush while marking out.
Has any one removed or trimmed the strip to allow it to sit flush ?
Presto
13th September 2013, 03:19 PM
I removed the strips completely. The only pain is the glue, but a 'caramel wheel' in a battery drill makes short work of it! :)
loanrangie
13th September 2013, 03:26 PM
I removed the strips completely. The only pain is the glue, but a 'caramel wheel' in a battery drill makes short work of it! :)

Thanks, i think i will do a rough mark out then trim the strips back.
loanrangie
15th September 2013, 11:01 AM
Past the point of no return, are the flares meant to sit on the guards or does the lower lip sit below the cut ?
I have placed it level with the body line as per Tim's guide but the lower rear (front flare ) still seems to hang down too low and the screw hole barely reaches the body work., or is it meant to meet the plastic sill which i have removed.
Presto
15th September 2013, 11:17 AM
The flare should not sit on the panel. The lower edge of the flare should fit over the panel, as it also prevents the panel cutting into the tyre should they touch.

Have a look at my images of the arch install:
http://www.aulro.com/afvb/gclro-members-rides-projects/111359-prestos-1995-d1-v8i-3.html

The front flare lower screw is very close to the bottom of the panel, but you'll see in my thread that I had a couple of goes taking more out of the panel at the back edge to provide more clearance for the tyre. I had to force the flare back a bit, but in doing that it does lift that back edge a touch.

Hope this helps!
loanrangie
15th September 2013, 11:19 AM
The flare should not sit on the panel. The lower edge of the flare should fit over the panel, as it also prevents the panel cutting into the tyre should they touch.

Have a look at my images of the arch install:
http://www.aulro.com/afvb/gclro-members-rides-projects/111359-prestos-1995-d1-v8i-3.html

The front flare lower screw is very close to the bottom of the panel, but you'll see in my thread that I had a couple of goes taking more out of the panel at the back edge to provide more clearance for the tyre. I had to force the flare back a bit, but in doing that it does lift that back edge a touch.

Hope this helps!

Thanks mate, just been checking out your pics and i assumed it sat over the cut as it then fits snug to the guard that way, was about to put the 2 top screws in but thought i better have a quick look on here before i **** it up.
loanrangie
22nd September 2013, 07:47 AM
Finished cutting and flares are mounted for a trial fit before trimming the bumper strip adding the piping for the flare, i probably took a bit longer as i can see that it would be easy to cut too much off.
Just need to paint the cut steel of the rear doors and fill the gap with a length of square rubber, if flexi had made the lip part of the flare about 20mm longer it would have covered the cut and you could then trim it back if required.
Doesnt look too bad with the 245/70's but the 265/75's should fill the guards a bit better.
loanrangie
22nd September 2013, 04:49 PM
Almost done, just need to finish of the doors. I went to Clark Rubber and got some 19mm sq section to fill the gap in the door and some Ford pinch weld to help with crap ingress. Still need to paint the steel and find some matching screw caps as the sealed packet was short 2 caps and 2 screws.:mad:
loanrangie
28th September 2013, 05:21 PM
All done :).

https://www.aulro.com/afvb/images/imported/2013/09/223.jpg