[Mordachai]

I think I can pull it off, I'm a moldmaker by trade and have made much more complicated molds than the fender(see avatar). I just am not familiar with 4x4's with bigger tires, or how much articulation they have. I'm trying to find out if vertical clearance or horizontal clearance is more important. I know when I'm looking for obscure or hard to find items I always think if I could just get ___________ ...
I'm trying to find what people who do a lot of offroading would like.

Once I know what size to make, I can fab the part and molds.

vtblazer- do you mean the lip around the headlight/grill, or the lip around the wheel. I think the lip around the wheel is easier, I can just section it with an extra fender. The thing with the lip around the grill is that it changed over the years...
I'm going to design the mold so that front part can be made for the different 'lips'.

Oh, once I have a set of fenders finished, I will be looking for a 4x4 in the area I can 'borrow' to mock up some inner fenders to match. The inner would most likely be made of a flexible plastic,like urethane, ABS, or PE/HDPE