Things have been progressing with our Jeep Grand Cherokee WJ Project. After finding a relatively inexpensive WJ on Craigslist with very little off-road mileage, we went to work building it into a more capable off-roader.

Although WJ is the last solid-axle Grand Cherokee by Jeep, it still has some inherent limitations for off-roading. One of the biggest obstacles is its lack of ground clearance and space for fitting larger, off-road tires. We addressed that issue with Bushwacker’s Cut-Out Fender Flares, and we then found a reasonably priced paint job from a local MAACO in Southern California.

With paint completed and the Bushwacker flares installed, we headed over to SoCal SuperTrucks in San Bernardino to install our BDS Suspension 4-inch lift kit. With the added ground clearance of the lift, along with the added space gained in the wheel wells during the Bushwacker fender flare installation, we would be able to fit a 33-inch off-road tire on our WJ; without the fender flares, BDS says a 31-inch tire can fit with its 4-inch lift. Although it’s not as easy to fit larger tires on the WJ as it would be with, say, a Wrangler, considering the stock tire size is only about 29 inches, the larger tires will help get the WJ off the ground and provide much better clearance for rocks and uneven terrain on the trail.

Previous Project WJ Stories
Bushwacker Fender Flare Installation and MAACO Paint

BDS 4-Inch Lift Install at SoCal SuperTrucks 

Before we install our Mickey Thompson tires and wheels, we wanted to get a few small, but important, details in order. If you’ve followed the build, you may remember seeing a few shots of the WJ minus some of the side cladding. We originally had to trim the cladding on the rear doors to accommodate the new Bushwacker flares. Since we had recently painted the Jeep, we wanted to wait to reinstall the cladding until we were certain of our next move. We considered trying to purchase black cladding direct from the dealer that would replace the grey pieces we have and also match the Bushwacker flares, but we quickly realized this route is unrealistic due to the cost of the pieces (don’t event ask). The next option was to find a donor vehicle at a junkyard, and we did find a few but the pieces were faded or the same grey we already had. 

After some digging around, we came across a few different forum topics on the subject where owners had painted the cladding themselves. Closer inspection revealed a number of positive experiences with Krylon Fusion spray paint. Designed as a no-prep paint that adheres to plastic, the Krylon Fusion option looked like a realistic, and cost-effective, route assuming it wouldn’t easy flake off or look poorly painted like the few examples we’ve seen over the years.

So we went ahead and picked up a few cans of Black Gloss Krylon Fusion. The key to success with any type of painting lies in the prep work, and we learned the hard way at first that poorly prepped plastic won’t accept paint well. We tested our cut cladding pieces first before going any further. We cleaned both well with a degreaser, dried them and applied three coats on each piece. Although one came out nicely, the other, which we tried unsuccessfully to sand between coats, looked messy and lumpy. 

With one of our sample pieces looking horrible and the other good until an accident that happened before the coat dried, we set out cleaning the cladding and starting over. We discovered the key to cleaning the plastic best is to do so with mineral spirits (or something comparable). Applying light, even coats, of paint also important as opposed to trying to apply a heavy coat or two. Multiple light coats provided a finish that looks natural and doesn’t look like it is painted with a rattle-can. The Fusion paint certainly adheres well to the plastic. If prepped properly and painted with multiple coats, the finish and appearance looks great.

So, we set off tape off the Jeep to paint the rest of the cladding. Although we plan to replace it in the future, we went ahead and painted the front fender as well to match. The chrome grill was starting to show signs of wear, so instead of buying a new replacement piece, we decided to pull it off, sand it down, and paint it black to match the rest of the cladding, flares and bumper (it’ll also match the Mickey Thompson Sidebiter II wheels we will be installing shortly) .

With so many miles on our WJ, the headlights have gotten cloudy over the years, so we grabbed a bottle of Meguiar’s PlastX to help clear it up. Comparable to extremely fine sand paper, Plastx is designed to clear up light oxidation, light scratches, grime and chemical contamination. Application of Plastx is simple enough with a rag or polish sponge. We taped off the edges to avoid contact with our new paint and went to work. The PlastX made an improvement with the cloudiness after one application, but we do need a little more help and will need to try the more in-depth Heavy Duty Headlight Restoration Kit down the road.

After applying multiple coats of paint to our WJ’s fender flares, bumper and grill, we came away impressed with the look and finish of changes. The Krylon Fusion does in fact work very well for painting plastic pieces, and with the proper prep work it appears durable as well. We’ve had the paint on our Jeep for over a month, and in that time we’ve washed the vehicle a few times and have yet to notice any signs of wear on the paint. We’re looking forward to seeing how it holds up to nicks and scraping on the trail, but for now we’re pleased with the simple solution.

Previous Project WJ Stories
Bushwacker Fender Flare Installation and MAACO Paint

BDS 4-Inch Lift Install at SoCal SuperTrucks