Fender And Inner Fender Swap
1. In the November '94 issue of Car Craft ("Fine Lines," p. 28), we gave you the info on how to install a new fender. But, in doing the fender swap we discovered that our plastic inner fenders were complete junk. At the time we didn't know of anyone who was reproducing these items--but we've since learned that Original Parts Group is now making them for our Chevelle. GM discontinued production of O.E.M. Chevelle fenders, so we had to scout around to find a set squirreled away in somebody's warehouse. We snagged one of the last sets of '70 Chevelle fenders from D&R Classic Automotive, but it still has many other year/make/model fenders available. To start the inner fender swap, remove the fender after loosening/removing the fender bolts. Before actually removing the fender, take note of the number and placement of fender shims. | 
2. The O.E.M. plastic inner fender is held on by various small bolts. Most of the bolts must be threaded out from below, such as these tucked away under the front bumper/radiator core support area. In addition, two bolts that reside directly rearward of the front tire must be removed. Many of the inner fender bolts will be rusty and hard to remove after having the tires sling mud and water on them for the past 20-something years. We recommend purchasing a new front end fastener kit (PN FE21800) from Original Parts Group. Trust us, it saves frustration in the long run. |
3. Once the bolts are removed, the inner fender should come off easily. After trying to remove the inner fender, we found that other non-related items (such as wiper and smog canister hoses) were still attached to the inner fender. The hoses were easily removed after disconnecting a few plastic holding straps. | 
4. Before installing the new inner fender liner on the car, we installed new inner fender clips that were part of our front end fastener kit. Using new fasteners and clips makes for a super-easy install; plus it gives our rig a clean, professional look. |
5. Set the new inner fender in place while taking particular care not to pinch/cut any hoses and/or wires. Then, begin threading in the various mounting bolts. In our case, the reproduction inner fenders fit perfectly, and all of the bolt holes were spot-on. It's almost a shame the new inner fenders look so nice, because it makes our gunk-covered engine bay look that much worse! We'll clean and paint our engine bay when our low-buck rebuilt engine gets dropped in next month. Stay tuned. | 
6. We installed the new D&R fender just as the old unit came off. Remember that the new inner fender has to slip inside of the fender's wheel opening lip, so you may wish to have a buddy help get everything fitted correctly. When bolting on the new fender, we used the new bolts from our front end fastener kit rather than the crusty old ones. |
7 A&B. The inner fender is secured using various locations on the body. Photo A shows us inserting two bolts through the inner fender into the firewall. Photo B demonstrates how the inner fender to the fender itself. Threading in and tightening all of the inner fender bolts is super-easy and straightforward. No degree in rocket science is needed. |  |