THE Roll Cage Thread

[AggieTJ2007]

I figured a thread dedicated to the most important safety item in an off-road vehicle was needed.

a few basics on building roll cages

you can use sch40 also known as poop-pipe but it is not recomended and you will die

I like to use either DOM or HREW structural tubing, it is designed to be structural not to carry fluid/liquids. I use 1-3/4" but it really depends on what dies are available for the bender you will be using.


I figured that I would post some pictures of the Toyota cage that I am building at work and some others to give some ideas of how to build a roll-cage that both looks nice and will protect you in a roll over.

Some designs will be very simple and other more elaborate but always remember triangulation is your best friend in roll cage construction.

here is my bender
http://i46.photobucket.com/albums/f124/CreightonRea/Toyoda/2010-02-03185258.jpg

and the begining of the Toyota cage the double B-pillars
http://i46.photobucket.com/albums/f124/CreightonRea/Toyoda/2010-03-16133700.jpg
http://i46.photobucket.com/albums/f124/CreightonRea/Toyoda/2010-03-16133643.jpg

oh and it fits in a standard cab truck

[4-Banger]

I think someone already made a thread about this...


...oh yeah, you :flipoff2:

[AggieTJ2007]

stupid forum, edited and it reposted fixed it

[bcolman]

is that for curry's rig?

[AggieTJ2007]

yeah its for his rig, it will be dove nosed and dove tailed with full fenders, kinda like a mini version of the beast

[bcolman]

looks good

[agjohn02]

I'm not crazy about those load paths but it's a cool looking cage.

[Seth]

Please don't have mention of poop pipe in a roll cage thread...

[AggieTJ2007]

I'm not crazy about those load paths but it's a cool looking cage.

yeah I realized that it would have been stronger to have the nodes (is that the correct term) closer together when I built it but I wanted it too look cool and I think that it will be plenty strong in a light toyota

[agjohn02]

yeah I realized that it would have been stronger to have the nodes (is that the correct term) closer together when I built it but I wanted it too look cool and I think that it will be plenty strong in a light toyota

agreed

[AggieTJ2007]

here is a good thread on pirate with pictures of a bunch of different cages albeit in TJ's but it is a good representation of basic cages and some more extreme cages

http://www.pirate4x4.com/forum/showthread.php?t=564706

[KrazyKarl02]

Just for reference, I have a Pro tools HD bender with the copperhead fab "harbor freight" air cylinder kit. It works good, and I like it for the price. The copperhead fab kit left a little to be desired (lots of torch slag) However like I said, for the money I have in it, I can not complain. I think for the home DIY guy it is a great option.

[robertf03]

the term triangulation should only be used in terms of location identification, I dismiss your abilities as a fabricator if you use this term when discussing structural design

those curves that make a half assed heart shape are pointless in that design. I give it a D

[AggieTJ2007]

so what is the correct term Mr. Engineer

sure they may not be structural but it looks nice in the truck

[Eckert]

whats wrong with a $400 cage from all-pro, marlin, etc? it only has to save your life once.

looks like you have $400 in material just for a B-pillar.

[agjohn02]

the term triangulation should only be used in terms of location identification, I dismiss your abilities as a fabricator if you use this term when discussing structural design

those curves that make a half assed heart shape are pointless in that design. I give it a D

how do fabricating abilities and structural design relate again?

[uglyota]

that is supafly.
Were you able to do much of that notching with a notcher or did you do most of it with the grinder?
Bender stand is kick ass too.

[AggieTJ2007]

whats wrong with a $400 cage from all-pro, marlin, etc? it only has to save your life once.

looks like you have $400 in material just for a B-pillar.

there is nothing wrong with those cages

and i only have $150 in material in that cage

most of the notches are done with the notcher but the long notches had to be done with a grinder but after the first one they are pretty easy

[KrazyKarl02]

I am planning on making some front suspension components with tube, but do to the klogger's weight and my driving style (I do not recognize "bump it" I recognize foot on floor, full throttle) I would like to make them out of .250 instead of .120 wall. I have a 6" - 1-3/4" - 110 degree die. I know it bends .120 wall. My question is, will this bend .250 also. The OD for .120 and .250 should be the same. Anyone know?

[bcolman]

the diameter will be the same if you get tube, but not if you get pipe

as for your bender bending it, i am not sure

[TdmayfieldIV]

I need one bad.......i'd rather not die

http://www.youtube.com/watch?v=umNMMqFtNOE

[RCcola55]

yes it will bend it fine as long as your ram is up to it

[AggieTJ2007]

I need one bad.......i'd rather not die

http://www.youtube.com/watch?v=umNMMqFtNOE

I am sure that someone has some tube that they would sell you and ask Sharpe or Rhino to help you build a cage. You can build a basic 6 point cage in a weekend and if you aren't a great welder you could work out a deal and I am sure Rhino or one of the other guys would help you weld it.


Or best option. drive to steamboat and I will sell you some tube and bend/weld the cage up for you for beer and pizza

[TdmayfieldIV]

hmmm....make a summer trip to the springs to see my friends and get a roll cage.......

[colman]

weve got 2 sticks in the garage i think brian would part with. he will probably pipe in after this post with more info

[bcolman]

ill sell it to you for what i bought it for

[TdmayfieldIV]

pm me

[RCcola55]

im kinda full with projects right now but after tcc i can do a cage

[colman]

yay, more crap out of the garage possibly

[DRAGOONRANCH]

There is a place in Waco that is supposed to start stocking DOM and they will have a discount for Cen-Tex off-road members (hmm, I wonder who might be one of those ;) ). I will find the name of it later.

[DRAGOONRANCH]

From the Cen-Tex boards in Waco

http://centexoffroad.com/forum/viewtopic.php?f=2&t=1034&sid=8d6873623331f3dd35be46a829c3a311


Picked up the steel today, and it looks like the DOM will be ~$2.97/ft. He will start with ~100ft in stock, they usually come in random 18-24' sticks.

[FJAggie07]

Damnit why did you have to move up to colorado???

I need a cage on the Tacoma after my little "incident" at K-Rocks.

[DRAGOONRANCH]

Plan a wheelin trip up there and drop it off, then plan another for when you go pick it up. ;)

[FJAggie07]

hmmm amanda's grandparents have a place in Steamboat... could give me an excuse to go up there...

[DRAGOONRANCH]

hit the road jack...

[AggieTJ2007]

it is a great idea bring it up here, I will even bring it back to you

[stx4wheeler]

I finally decided to put my tubing bender together after letting it set in boxes for the last year and a half. I built the stand similar to Karls, but added a tray for dies and equipment. I used the Copperhead Fab kit to convert it to air/hydro. Bender is a pro tools 105hd with degree ring, and stop. Now its time to start bending tube.:gigem:

[85cj7]

looks nice kevin

[uglyota]

Nice! Replace that tray with expanded metal, add 2 cupholders (one for lube other for barleypop), and add some adjustment to those casters and you should be in good shape

:flipoff2:

just jealous I don't have a garage or that big of a hard surface to wrench on :(

[RCcola55]

bring it to cs for a weekend

[breckboarder55]

I am sure that someone has some tube that they would sell you and ask Sharpe or Rhino to help you build a cage. You can build a basic 6 point cage in a weekend and if you aren't a great welder you could work out a deal and I am sure Rhino or one of the other guys would help you weld it.


Or best option. drive to steamboat and I will sell you some tube and bend/weld the cage up for you for beer and pizza

What about my a cage for my TJ?

I don't know how to weld, or have access to a bender...

However, there are tons of pre-fabbed kits available. They are a bit pricey at $700-$1000, but are already cut, notched, and bent. I am not interested in one of the bolt in "sport cages".

Thoughts?

[bburris]

They might be cut, notched and bent, but they don't tell you how much more cutting, notching and fitting you'll have to do to get it to fit in your Jeep. I ended up throwing the front center spreaders that came with my kit away and having two new pieces redone locally because the ones supplied with the kit were too short and to fit them to the center hoop would have made them worse.

[85cj7]

kits are fine, I did the poison spyder customs cage for my cj and like it a lot. I still think that a lot of the cage kits need some extra bracing but those parts are all straight pieces and gussets that don't require a bender.

here is a cheap option for you. http://www.poisonspyder.com/catalog/product_info.php?cPath=82_83&products_id=264
keep in mind this would be pretty much a one time flop cage though. You could make it last with added door bars and plenty of bracing.

[uglyota]

do the "drive to steamboat" option. I'll come up and help.
Or get the dexter kids to help you and you'll learn how to do all that stuff.
Hell I bet Lance would let Ryno build you a kustom cage for $700

[breckboarder55]

kits are fine, I did the poison spyder customs cage for my cj and like it a lot. I still think that a lot of the cage kits need some extra bracing but those parts are all straight pieces and gussets that don't require a bender.

I really like your cage, and they make a version for the TJ.


I need something that is going to work with the factory top.
I do not want to put something in, and junk it two years later to go with something better.
Although I do not have a back seat right now, I like the option of being able to still have passengers in the back.
I prefer the idea of using sanctions vs. cutting up the dash.


I would really consider taking the trip to Steamboat. I was planning on going to CO in August anyway. If I make that trip, I will not have an extra thousand to spend on a roll cage though.

Options for pre-fabbed kits:
http://www.genright.com/category.aspx?categoryID=116
http://www.poisonspyder.com/catalog/index.php?cPath=82_83&osCsid=0181156c414eb9770b56acd2c7f4e5d3
http://www.polyperformance.com/shop/Poly-Performance-Jeep-LJ-TJ-Cage-Kit-p-20215.html
http://www.atozfabrication.com/store/home.php?cat=260
http://bluetorchfab.com/store/product_info.php?cPath=100&products_id=453

Or fabbed cage by Creighton or Dexter

Appreciate the help guys. :beer:

[uglyota]

the cage will probably cost you more like $200 + a bar tab if you come up to Steamboat.
My weekends in August are filling up quick though. Don't know what Creighton's schedule's like.
Do it...

[RCcola55]

do the "drive to steamboat" option. I'll come up and help.
Or get the dexter kids to help you and you'll learn how to do all that stuff.
Hell I bet Lance would let Ryno build you a kustom cage for $700

hell we have a bender at the house, just cover material and welding fluid as well as being able to help and im sure we can get one done. There is going to be a lot of tube bending coming up betwee my cherokee, ranger and pigpin, im sure we can find time


i do like this one though but kinda pricey....
http://www.genright.com/category.aspx?categoryID=116

[Hot Pocket]

Kind of on the same topic...

I wanted to get some tube bumpers for the bronco. In the rear I just want some square tubing that will go flush up against the body, almost like a roll pan-esque job. In the front, mostly the same thing with a tow bar.

If I come visit the Dexter hizzy, is there any way one of you could point me in the right direction as far as what kind of tubing to get etc?

I dont mind supplying tube, welding fluid, pizza, & beer :)

[uglyota]

hell we have a bender at the house, just cover material and welding fluid as well as being able to help and im sure we can get one done. There is going to be a lot of tube bending coming up betwee my cherokee, ranger and pigpin, im sure we can find time


yeah but if he paid lance to have you do it you could make some monez and get a break from doing bootyfab lifts on donks :flipoff2:

[agjohn02]

welding fluid... & beer

is that redundant or are you just dumb?

[AggieTJ2007]

I really like your cage, and they make a version for the TJ.


I need something that is going to work with the factory top.
I do not want to put something in, and junk it two years later to go with something better.
Although I do not have a back seat right now, I like the option of being able to still have passengers in the back.
I prefer the idea of using sanctions vs. cutting up the dash.


I would really consider taking the trip to Steamboat. I was planning on going to CO in August anyway. If I make that trip, I will not have an extra thousand to spend on a roll cage though.





Options for pre-fabbed kits:
http://www.genright.com/category.aspx?categoryID=116
http://www.poisonspyder.com/catalog/index.php?cPath=82_83&osCsid=0181156c414eb9770b56acd2c7f4e5d3
http://www.polyperformance.com/shop/Poly-Performance-Jeep-LJ-TJ-Cage-Kit-p-20215.html
http://www.atozfabrication.com/store/home.php?cat=260
http://bluetorchfab.com/store/product_info.php?cPath=100&products_id=453

Or fabbed cage by Creighton or Dexter

Appreciate the help guys. :beer:

Bring it to Dallas in July or August and we can get you hooked up. It will probably be about 200ft of tubing to make a full cage and about a week of work plus painting if you want it really nice like Johns

go through this thread and pick out a cage that you like or different parts that you like and we can build whatever you want
http://www.pirate4x4.com/forum/showthread.php?t=564706&highlight=cage+inspiration

PM me if you have any more questions

[sam_hodnett]

I eventually want to put a cage in the dakota... and a new drivers side floorboard

[85cj7]

I really like your cage, and they make a version for the TJ.


I need something that is going to work with the factory top.
I do not want to put something in, and junk it two years later to go with something better.
Although I do not have a back seat right now, I like the option of being able to still have passengers in the back.
I prefer the idea of using sanctions vs. cutting up the dash.


I would really consider taking the trip to Steamboat. I was planning on going to CO in August anyway. If I make that trip, I will not have an extra thousand to spend on a roll cage though.

Options for pre-fabbed kits:
http://www.genright.com/category.aspx?categoryID=116
http://www.poisonspyder.com/catalog/index.php?cPath=82_83&osCsid=0181156c414eb9770b56acd2c7f4e5d3
http://www.polyperformance.com/shop/Poly-Performance-Jeep-LJ-TJ-Cage-Kit-p-20215.html
http://www.atozfabrication.com/store/home.php?cat=260
http://bluetorchfab.com/store/product_info.php?cPath=100&products_id=453

Or fabbed cage by Creighton or Dexter

Appreciate the help guys. :beer:

i remembered you had asked about this and when I stumbled this link I thought I would let you know. Seems like a really low price.
http://www.kozoffroad.com/pages_catalog/rollcages/tj/tjrollcages.htm

[85cj7]

this is possibly the ugliest jeep cage I have ever seen
http://www.texas4x4.org/showthread.php?t=35414

[MR.ZAP]

this is possibly the ugliest jeep cage I have ever seen
http://www.texas4x4.org/showthread.php?t=35414

Hahaha, I'll keep my roll bars, thanks :gigem:

[DRAGOONRANCH]

It didn't look that bad in his heep if I recollect correctly. Just sayin is all.

[85cj7]

It didn't look that bad in his heep if I recollect correctly. Just sayin is all.

There is a pic of it in the jeep if you scroll down to the bottom of the thread. It is entirely too high, plus leans forward so you can't run the windshield frame, and it ends short so that the back is entirely useless. It works, but like I said is probably the ugliest jeep cage I have ever seen. It would have looked better and accomplished the same safety goals to just add a front hoop and some spreaders.

[DRAGOONRANCH]

Well, it was in a heep so that there takes it into that :rainbow: category to start with. :flipoff2:

[bcolman]

the guy that is selling it is also tall, when he was in the jeep it didnt seem to look too awkward, but it did look a little tall