Bushwacker Smooth Fender Flares | Premium Paint-to-Match Protection
Our Smooth Fender Flares combine premium protection with a factory-quality finish that’s ready for paint. Crafted from our proprietary Dura-Flex 2000 TPO material, these flares resist cracking, warping, and UV damage while delivering up to 2.5 inches of additional tire coverage.
We engineer bushwacker smooth fender flares from Dura-Flex 2000, a thermoplastic olefin formulation designed specifically for automotive exterior use. This material maintains flexibility across temperature ranges from -40°F to 140°F without cracking or becoming brittle.
Fitment & Installation Specifications
Each Bushwacker Smooth Flare set is designed for a specific vehicle year, make, and model. We manufacture truck-specific kits and SUV-specific kits with mounting brackets that align with factory body holes—most applications require no drilling.
Installation hardware includes stainless steel bolts, washers, and brackets along with vehicle-specific instructions showing torque specs and mounting sequences. The flares attach directly to existing mounting points along the wheel well lip. Average installation time runs 2–3 hours with basic hand tools.
Paint Preparation & Finishing
Surface Prep
Clean each flare with automotive wax and grease remover, then scuff the entire surface with 320-grit sandpaper to create mechanical adhesion. Wipe down with a tack cloth before applying primer.
Primer & Paint
Use a flexible automotive primer designed for TPO plastics—standard primers may crack as the flare flexes. Apply 2–3 light coats, allowing flash time between each. Follow with your vehicle’s color-matched automotive paint in thin, even coats.
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Common Questions About Bushwacker Smooth Fender Flares
No, Bushwacker Smooth Fender Flares ship in an unpainted matte black finish ready for primer and paint. The smooth surface is designed specifically for customers who want to match their vehicle’s factory color.
You’ll need to prep the surface by cleaning, scuffing with 320-grit sandpaper, and applying a flexible TPO-compatible primer before painting. This process allows you to achieve a perfect color match using automotive paint from your local supplier.
Most Bushwacker Smooth Flare applications are designed as no-drill installations that use existing factory mounting points. The vehicle-specific brackets and hardware align with holes already present in your wheel well.
A small number of applications may require drilling 1–2 additional mounting holes for optimal stability. Your fitment guide will specify whether your particular year, make, and model requires any drilling before you begin installation.
Bushwacker Smooth Fender Flares typically add 1.5 to 2.5 inches of coverage beyond your factory fender lip, depending on your specific vehicle application. This measurement represents the horizontal extension from the original body line.
The exact coverage amount varies by vehicle because each application is molded to follow the unique contours of that truck or SUV model. Check your vehicle-specific fitment guide for precise coverage dimensions.
Yes, you can install the flares first to verify fitment and alignment, but we recommend removing them for painting. Test-fitting before paint ensures proper clearance with your wheels and tires and lets you make any necessary adjustments.
Once you confirm everything fits correctly, remove the flares to prep and paint them off the vehicle. This approach prevents overspray on your truck and allows better access to all flare surfaces for even paint coverage.
Use a flexible automotive primer specifically formulated for TPO or thermoplastic substrates. Standard primers designed for metal will crack as the flare material flexes during temperature changes and impacts.
Follow the primer with automotive-grade paint in your vehicle’s color code—most auto parts stores can mix the exact factory match. Finish with a flexible clear coat for added UV protection and gloss retention. Avoid household spray paints, which won’t bond properly to the Dura-Flex material.
Yes, Bushwacker Smooth Fender Flares meet DOT requirements for fender coverage in all 50 states when properly installed. Most states require fender coverage that extends at least to the widest point of your tire tread.
These flares provide sufficient coverage for lifted trucks and oversized tire combinations while maintaining street-legal compliance. Verify your local regulations regarding tire coverage width to ensure your specific wheel and tire setup remains compliant after installation.
Dura-Flex 2000 is engineered to withstand temperature extremes from -40°F to 140°F without cracking or warping. UV inhibitors blended throughout the material protect against sun damage and fading for the life of the product.
Our accelerated weathering tests simulate over 10 years of continuous sun exposure, salt spray, and temperature cycling. Real-world installations in desert, coastal, and winter climates have confirmed the material maintains structural integrity and appearance beyond a decade of use when properly maintained.