DIY Fender Seals for under $40

Intro
I decided to replace my fender seals after removing them for maintenance work, and discovering the poor condition they were in. I have seen many people say they remove there's and it's not a problem. If you do a lot of off-road eating or gravel road driving, it stands to reason you may benefit from including these fender seals. This guy reported his airbox getting filled up with dirt more easily without the fender seals.
https://www.tacomaworld.com/threads/suttonkb-double-cab-sas.431672/page-3#post-13404919

You will want to make your own because dealerships will quote you prices anywhere from $100-$200 and buying the OEM item and installing it yourself will still cost you around $60 not including the cost of clips.
https://partsfactory.camelbacktoyot...eal&scat=&p=catalog&mode=search&search_in=all
https://radrubberdesign.com/product/tacoma-1st-gen-1995-2004/

Alt names
For the sake of making this post more easily searchable, I'll include some common terms I've seen referencing these parts, since you really can't figure out the name of them until you look on a parts fiche. If you think of others, let me know and I'll add them to the list.

apron seal
mudguard
splash guard
mud flap
rubber skirt
rubber flap
wheel well apron

Material
The first decision is to figure out what material you want to use to replace the rubberlike of the OEM flaps. I've seen others post about using anti-fatigue mats, but I think that will probably cause issues because the material is too thick for the clips, and may not be resistant to heat and oil. This guy used a pond liner, which is probably a good idea. But it costs a lot more and you'll wind up with way more material than you need.
https://www.tacomaworld.com/threads/flap-in-the-front-wheel-wells.216851/#post-4993942

I settled on a sheet of PVC intended as a flooring cover. The thickness is similar to the OEM fender seals, and I'd like to think the PVC will be robust. It is much cheaper than I have seen other materials people have used, and there is more than enough to do a full set of fender seals and still have something left over for other projects. It's pretty tough since it has a crisscrossing fiber within its matrix, and has an attractive shiny side with a diamond plate-like surface
Item # 847656 Model # 7520212DP
Tenex 27-in x 72-in Black Pvc Plastic Sheet Multipurpose Flooring
https://www.lowes.com/pd/Tenex-27-i...lastic-Sheet-Multipurpose-Flooring/1000265919

Procedure

• First I will describe how I cut and fitted the sheets, and then I will tell you how to do it better.
• I jacked up the body of the truck so I would have more distance between the fender and the wheel to work with.
• I traced the old fender seals onto the new material and roughly cut them to the same shape.
• Using an awl, I poked holes through the PVC sheet where the holes in the frame and body were for the clips. I then drilled them out to make them bigger.

How to do it better:

• Trying to fit these pieces with the wheel on was an absolute killer to my back and knees. I strongly recommend removing the wheels entirely. It will be much easier on you and you will likely do a better job of cutting and fitting the new fender seals.
• For this particular material, a drill bit does not do a good job of making a hole. It always leaves a large chad behind that will make the material thicker and harder for the clip to hold it in place. The guy that use the pond liner above used a makeshift punch to make the holes. I strongly recommend getting some type of hole punch. Unfortunately this does add to the cost, as the item I would recommend for this is $9 at Harbor Freight.
• Don't try to replicate the OEM fender seals. They are in multiple pieces for no particular reason, and I suggest for the sake of endurance, to make it all one big piece. I also think the OEM fender seals could fill in more gaps, so I made mine in a nearly completely different shape.
• Some people recommend using cardboard to make a template and then using that to cut out the sheet, but I don't think this is necessary. Just cut a piece roughly the size you need with several extra inches, use a couple of clips to hold up each corner and then cut to shape.
• If you just want the stock shape, you can print out the templates provided here:
  https://www.tacomaworld.com/threads...vmhIbyk2ZQrIM8RfBXWgvgpJJrKsP68#post-12087348
  
• Use a Sharpie Metallic Marker, in silver color, to trace any patterns you want to use.

Clips
You'll need to buy new clips because the old ones are old and they will likely break when you remove them. The number of clips you use will be determined by how big you make your fender seals and the availability of holes. I suspect I used about 30 total clips.
This particular clip is supposed to be this similar dimensions as the OEM clips of 7mm dia, and 13 mm length:
Trim Panel Push Retainer Clip, for Toyota Lexus GM 90467-07041

$11 Autobahn88 Push-Type Clip, fits for GM,Geo Metro Tracker 1989-On,Suzuki,Toyota,Hyundai (OEM: 96057846, M619582, TQ696C07, 09409073085PK, 9046707041, 8615522000) (Pack of 20)

https://www.amazon.com/dp/B07HFTP22G

I also had another set of clips for a Nissan that I found useful because not all holes in the frame and fender are the same size. These did a better job of holding the fender seals in place when some of the holes were larger:

CIKIShield 50 Pcs Retainer Clips and One Plastic Fastener Remover - Stronger Than Original

https://www.amazon.com/dp/B071FZQRC2
Head dia: 20mm; stem length: 9mm & fits: 8mm (5/16") hole

Also note the last kit comes with an angled fastener remover. This is definitely a tool you want to have in your inventory anyway, and it does a much better job of removing these plastic pop rivets without breaking them.


Other thread about the clips:
https://www.tacomaworld.com/threads/clip-size-for-front-fender-apron-seal.441043/
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Another example using similar material:
https://www.tacomaworld.com/threads/cheap-fender-apron-fix.451005/#post-13225555


Here are my fender seals. The next time I have the wheels off I plan to completely redo them with the above recommendations. You can see the combination of clips I used.

 

Nice write up.

 

Nice! I would've went this route if I had seen it before ordering:

https://geartechcustoms.com/shop?olsPage=products/1st-generation-tacoma-engine-splash-guards-95-04


Nice post - thanks for sharing!