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I found a 95 bronco that has rust along back fender well, I haven’t seen it in person but this looks like a common problem. Can I put cutout flares to cover this and treat the non rusted area?
 

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Yo Jjacochran,
Welcome!

See our Sponsor's 95 Bronco fender flares Sources at 1995 Ford Bronco Fender Flares - CARiD.com
Some replace entire rear quarter panel or as we did, a patch panel by welding or use of body adhesive.

Quarter Panel Patch & Inner Fender weld Replacement by BRONCONUT @ chop, cut & rebuild

Quarter Panel Replacement w/adhesive:
See 1986 FSB Restoration Project (56K Warning) by Xris @ 1986 FSB Restoration Project (56K Warning)
He used 3M Duramix Large Panel Adhesive for his 1/4 panels
"...the rockers I have go over the existing and up the door jamb. So I'll fabricate the missing spots (very minor) and use the Duramix in combination with pop rivets to give it added strength. This is the area which will be PRO 15ed as well as th rough Durabak coat...."

Quarter Panel Replacement w/adhesive Tip on an 86 by Sixlitre (Malcolm H, Eddie Bauer) at 1986 Ford Bronco Quarter panel adhesive pictures, videos, and sounds | SuperMotors.net

Others have used SEM 3M 8219 adhesive, etc.

Panel Repair- Eastwood's No-Weld Panel Repair Kit
Repairs with patch panels or custom fabricated panels utilizing our panel adhesive can be done with structural integrity far superior to rivets themselves. Repair fenders, quarter panels, trunk floors, firewalls, doors or floor.

ASAP, find out if speed control recall work, if equipped was completed. If you still have concerns about Recalls, please contact the Ford Customer Relationship Center:
US: 800-392-3673 | CA: 800-565-3673
Note: 3673 spells "FORD" on phone keys
For the hearing- or speech-impaired: Please contact the Telecommunication Relay Service by dialing 71
"Summary: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN. THIS COULD RESULT IN AN UNDERHOOD FIRE."
See this guide by jowens1126 to confirm recall status @ 93 & 94-96 Cruise Control Recalls Repair
Note that the 93 recall is different than 94-96.

1995 Bronco Dealer Brochure @ 1995 Ford Bronco

1995 Bronco Drivetrain, Powertrain Service Manual - Google Drive
&
1995 Bronco Chassis, Service Manual - Google Drive
To switch between folder list & grid views, click the button to the right of the "DOWNLOAD ALL" button in the upper right corner of the window) by HawkDriver

Haynes Red Manual for 80-95 Bronco & F Series @ Hanes guide 80-96 bko f series.pdf via BroncMom

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85 Bronco, 309ci I6 w/4bbl, np435, 4" lift, 37" Irok NDs, 4.56 w/ Detroit Locker and tru trac
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Yes you can use cutout flares to cover that up, once you cut it out.

The cutout flares for 87-96 are hideous banana shaped monstrosities. Instead, find a set for 80-86. Heres a set on my 85.



However, since the cutout flares add about 4" to the width of each side, Youll need new wheels or quality spacers to bring the tires out even with the edge of the flare.

Instead of this


The correct wheels or spacers give you this
 

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1994 Bronco XLT 5.0, E4OD, 31x10.5R15 BF Goodrich A/T on OEM Rims, Rust Resto w/Custom Suspension
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Following up on the OP's post, we're in the same boat with our '94 and I found these on eBay:

Black Textured Pocket Bolt Fender Flares 92-96 Ford F-150 F-250 F-350 Bronco | eBay

The specs say they'll add up to 2" additional coverage and I'm wondering if that will be too wide and make it look like the pics @BigBlue 94 posted. The plan is to cut out the rust on all 4 openings and mount the flares above the "flare" of the fender. We've got BFG A/T 31x10.5's on stock rims. Do you think those flares will look OK with the current tires or will it look like it's "wearing a skirt" as was stated in another fender flare post? I've thought about spacers if needed, but I've been advised they will put stress on...something...and cause it to wear out prematurely.

180726


Thoughts?
 

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85 Bronco, 309ci I6 w/4bbl, np435, 4" lift, 37" Irok NDs, 4.56 w/ Detroit Locker and tru trac
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Following up on the OP's post, we're in the same boat with our '94 and I found these on eBay:

Black Textured Pocket Bolt Fender Flares 92-96 Ford F-150 F-250 F-350 Bronco | eBay

The specs say they'll add up to 2" additional coverage and I'm wondering if that will be too wide and make it look like the pics @BigBlue 94 posted. The plan is to cut out the rust on all 4 openings and mount the flares above the "flare" of the fender. We've got BFG A/T 31x10.5's on stock rims. Do you think those flares will look OK with the current tires or will it look like it's "wearing a skirt" as was stated in another fender flare post? I've thought about spacers if needed, but I've been advised they will put stress on...something...and cause it to wear out prematurely.

View attachment 180726

Thoughts?
My flares are a good 4" wide, if not 5". They are cutout style and required cutting about 2-3" of fender out. With a only 31" tire I do think it might look like its"wearing a skirt". I have 37s on mine and I wouldnt want any smaller. I have the room for 42s!

Wheel spacers are an acceptable fix. There is really no difference between running a spacer or a wheel with very little backspace. What it does do is increase the scrub radius, which is the distance between the centerline of the tire and the center of the BJ. It can put undue stress on the BJs, but its really only an issue when you do large spacers. On a rear axle, they have no major side effects. Just gotta keep all the nuts tight.
 

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1994 Bronco XLT 5.0, E4OD, 31x10.5R15 BF Goodrich A/T on OEM Rims, Rust Resto w/Custom Suspension
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but its really only an issue when you do large spacers
What would be considered "large"? If the flare adds up to 2" of coverage then a 2" spacer would fix that.
 

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What would be considered "large"? If the flare adds up to 2" of coverage then a 2" spacer would fix that.
A 2 inch spacer is at the large end of acceptable. Anything bigger will put too much stress on the BJs.

With 2" spacers, I have about half an inch of the wheel hub showing plus the lockout. 3" would nearly cover the lockout.
 

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1994 Bronco XLT 5.0, E4OD, 31x10.5R15 BF Goodrich A/T on OEM Rims, Rust Resto w/Custom Suspension
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Thanks @BigBlue 94! Hopefully they won't come out too far then and a 1" spacer would be sufficient. Otherwise, we'll be looking at new tires and these are already new. Are your 37's on wider rims or stock?
 
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Thanks @BigBlue 94! Hopefully they won't come out too far then and a 1" spacer would be sufficient. Otherwise, we'll be looking at new tires and these are already new. Are your 37's on wider rims or stock?
You wouldnt need new tires. You would need new wheels with an inch or so less backspacing. Thats why I am not opposed to "smaller" wheel spacers. As far as the BJs and scrub radius are concerned, a 4.5" BS wheel with 2" spacer is NO DIFFERENT than a 2.5" backspace wheel. The difference is more fasteners that can potentially fail.

Bora makes great quality spacers, for automotive and agricultural uses.

My wheels are 16x8 with 4.5" of BS. I screwed up and should have ordered em with 3" of BS.

I would look for some thinner flares. Street style or something.

Mine are the bushwhacker cutouts. Look in this random pic of a bullnose. See that chrome trim around the wheel wells? Every bit of metal below that piece of trim is cut off on mine.

 

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1994 Bronco XLT 5.0, E4OD, 31x10.5R15 BF Goodrich A/T on OEM Rims, Rust Resto w/Custom Suspension
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Thanks for all the info @BigBlue 94!. Will post some pics once we get it done. Take Care!

Deuce
 
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Well, we got the flares in and are now concerned that they will be much too wide. Here's the right rear attached using butterfly clips:

181268
181269


Not sure if a 1" spacer will be enough. What are all the downsides of a 2" spacer? Is a more narrow flare our only other option?

Deuce
 

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Try em on the front before making any decisions. Those do look like nice flares!

I personally have no qualms with spacers 2" and under. Im running 2"ers on every corner.

One benefit to spacers that no one mentions is the increased airflow to your brakes, keeping them cooler.
 

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I personally have no qualms with spacers 2" and under. Im running 2"ers on every corner.
After doing a quick search on this site for spacers I am now concerned about them failing and causing an accident. The guys that are saying "no issues" have only run them for 1000-3000 miles. I see that there are a gazillion spacers for sale so it's obvious that tons are sold and installed/used. So why are the naysayers so adamant that it's a disaster waiting to happen? This thing is used as a DD and my 18 y/o is putting about 8-10K miles/yr on it. If we go with spacers does that mean no offroading? #concernedpapa 🤦‍♂️
 

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After doing a quick search on this site for spacers I am now concerned about them failing and causing an accident. The guys that are saying "no issues" have only run them for 1000-3000 miles. I see that there are a gazillion spacers for sale so it's obvious that tons are sold and installed/used. So why are the naysayers so adamant that it's a disaster waiting to happen? This thing is used as a DD and my 18 y/o is putting about 8-10K miles/yr on it. If we go with spacers does that mean no offroading? #concernedpapa 🤦‍♂️
Ive offroaded in Moab with mine... Done a 2200 mile road trip on them. They have 37s bolted to em and ive done upwards of 90mph. Ill be taking it to the dunes in August and itll get airborne, and likely keep on going. No i dont have 20k miles on em, but someone did, as i pulled 2 of mine off a truck in the junk yard.

Ill turn the question back around, how many of those naysayers have actually had a failure with a wheel spacer and how many are just blowing smoke? I have provided the pros and cons of wheel spacers and am not saying they are bulletproof. Its also not my kid. But I would be confident having them installed as long as they receive proper maintenance. In the end, YOU must weigh the pros and cons and make the decision that suits your family!
 

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Ive offroaded in Moab with mine... Done a 2200 mile road trip on them. They have 37s bolted to em and ive done upwards of 90mph. Ill be taking it to the dunes in August and itll get airborne, and likely keep on going. No i dont have 20k miles on em, but someone did, as i pulled 2 of mine off a truck in the junk yard.

Ill turn the question back around, how many of those naysayers have actually had a failure with a wheel spacer and how many are just blowing smoke? I have provided the pros and cons of wheel spacers and am not saying they are bulletproof. Its also not my kid. But I would be confident having them installed as long as they receive proper maintenance. In the end, YOU must weigh the pros and cons and make the decision that suits your family!
That's fair...and a valid point. And, for the record, I wasn't challenging you or your recommendation. Just "thinking out loud". I did do some further reading after posting that and found many more posts saying similar things. It appears to be like all things with these vehicles: buy quality, install correctly and maintain properly.

That said, the cost of good spacers seems to be close to the cost of a good set of rims. Although that's hearsay and I haven't started pricing rims at this point. And, I did as you recommended and dry-fitted the front flare this morning. It's definitely closer to lining up with the fronts than it does with the backs. I could probably make do with 1" spacers on the front and 2" on the back. Not sure how that would impact the ride and steering though. Lots to ponder though. And it seems we'll have more time to figure it out than expected. The guy doing the rust repairs can't get to it until September so we're in a holding pattern 'till then.
 
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That's fair...and a valid point. And, for the record, I wasn't challenging you or your recommendation. Just "thinking out loud". I did do some further reading after posting that and found many more posts saying similar things. It appears to be like all things with these vehicles: buy quality, install correctly and maintain properly.

That said, the cost of good spacers seems to be close to the cost of a good set of rims. Although that's hearsay and I haven't started pricing rims at this point. And, I did as you recommended and dry-fitted the front flare this morning. It's definitely closer to lining up with the fronts than it does with the backs. I could probably make do with 1" spacers on the front and 2" on the back. Not sure how that would impact the ride and steering though. Lots to ponder though. And it seems we'll have more time to figure it out than expected. The guy doing the rust repairs can't get to it until September so we're in a holding pattern 'till then.
I did not take offense to it. Its all good!

And yes, a good pair of spacers is close to the cost of new wheels. Since you have the time now, I would search for wheels too, just to weigh all options. Im sure you have noticed the stock on many things is low or nonexistent so plan accordingly.

On most trucks, the front axle is a couple inches wider than the rear. This helps mainly with turning radius. Having the entire axle and wheel assemblies the same width will not drastically affect handling.
 

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I did not take offense to it. Its all good!

And yes, a good pair of spacers is close to the cost of new wheels. Since you have the time now, I would search for wheels too, just to weigh all options. Im sure you have noticed the stock on many things is low or nonexistent so plan accordingly.

On most trucks, the front axle is a couple inches wider than the rear. This helps mainly with turning radius. Having the entire axle and wheel assemblies the same width will not drastically affect handling.
I've never shopped for wheels. What specs do I look for? We like the current design (Alcoa?) and will probably stay close to that. Is there a particular width or offset I'm looking for? Current tires are 31x10.5R15 BFG A/T and damn near brand new, so I'd like to keep them if possible.
 

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I've never shopped for wheels. What specs do I look for? We like the current design (Alcoa?) and will probably stay close to that. Is there a particular width or offset I'm looking for? Current tires are 31x10.5R15 BFG A/T and damn near brand new, so I'd like to keep them if possible.
It is best to remove one of your wheels and measure the backspace. Say you come up with a 4.5" measurement. Now knowing you want them to stick out farther, subtract how far from the original BS measurement. Say you want them 1.5 inches farther out, that would mean you want a wheel with 3" of backspace.

I completely ignore offset since its in metric and requires a bit more math to determine the backspacing from.

You should be looking at 15x8 or 15x7 wheels. Broncos use a 5 on 5.5" lug pattern.

The American Racing Outlaw II is very very very similar to the factory Alcoa 10 hole wheels. The AR-23 is also a great looking wheel on these trucks. US Mags Indy 101 5 slots look great too but are about twice the price of the American Racing wheels.
 
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