Fender Clearancing Zero Rubbing
Most of the time, it is the rear of the front fenders that dictates the size of the tire you can put on your truck. When you turn, this is the most common rubbing point and the bane of anyone trying to put on a larger tire without lifting one's truck any higher. Sometimes the bottom of the front factory bumper can get in the way too, but this is easily solved by either removing the factory bumper or using a chopsaw to clearance it. And this type of clearancing works well on steel fenders too, but a lot of times it can leave your fender looking a bit messy.
We explored three different options for clearing out fender steel where a tire would normally rub on 1999-2009 Super Dutys. The chopsaw idea works, but you could also go a much cleaner (and at the same time more legal) route of extended fiberglass fenders or Bushwacker cut-out fender flares for your truck too.
The easiest method of tire clearancing is to just cut out the metal that is rubbing your tires. This is very permanent and can leave your truck looking a bit hokey if you do not do a good job cutting. We did a marginal job because we knew we were going to eventually be replacing these fenders with fiberglass units or cut-out fender flares. Our first and definitely most relied-upon fender clearancing tool is a sawsall. You or your neighbor probably owns one of these. Just try not to get too saw-happy when you go for it.
Cut-Out Fender Flares
To greatly increase your fender clearance at all four corners, and keep your truck legal at the same time, you might want to look into a set of Bushwacker Cut-Out fender flares for your ride. Bushwacker has a variety of applications and their new flare are much more durable (and easily removable) than the ones they made in the past. They allow you to greatly increase your fender opening and give you the added protection over the tires to keep them legal in all states.
Your other option for extended tire clearance is to go with some replacement fiberglass fenders that bolt in place of your factory steel. These can take a fair amount of bodywork to get on correctly, but the results look great.