Been talking with Jungle Fender Flares the past few days on how to solve the fit of the flares.
They have been really helpful with information on how to proceed.
As Luke and I agreed on, they are in fact made from the 2door models of the Hilux.
But for those that order them for the 4 doors have modded them to fit.
Here is a picture that i got from them on how to have the rear flares fit better on the tray:
For the lip it self that fits inside the wheel-well, they say it should take shape once its bolted in place.
But, Fiberglass is to stiff to handle once cured, heating it up some should make it more flexible to bend and take shape.(Do not heat to much as it will melt the fiberglass!)
For the final adjustments of the fitment, having elongated holes where you bolt it in place in the original holes will help a lot when pushing it firmly in place and tightening the screws.
(This is something I did not think of when installing them, so i will reverse the install of the rear flares and cut away as they described, will have to wait till the weather gets better and warmer before attempting this).
I might also re-do the lip that fits under the wheel-well as i am not satisfy on how they fit right now.
Will update you when the time comes