Rollcage progress pics

I re read the thread didn't see, are you doing the bending? if so with what? Using .125 dom tubing?

 

David - The tubing I'm using is sold as 10 ga. x 1 7/8". The actual (measured) wall thickness is 0.118". I doubt that it's dom - there are no grade marking anywhere on the tubing.
I'm not doing the bending - a guy that has a muffler shop did it for $3 a bend ($52 total). When I did the layout on the plywood you may have seen earlier, I used a 6 1/2" centerline diameter for the bend radius (assuming that the die radius dimension on the bender was something common for all benders). Well you know what happens when you assume something! The die turned out to be about 4 1/2" diameter. When I saw the first bend, I almost choked - I hadn't bothered to even ask about the bend radius until after the first piece was bent. To make matters worse, the guy measured wrong on the second bend and ended up trying to straighten out a 90 degree bend - things were NOT looking good - luckily I took extra tubing with me.
To make everything as close to the layout as possible (long radius), the guy made two bends close together. Structurally, the bends are probably weaker than a good long radius, but it ended up working better than expected.
I have another crossbar that will tie the back together and then I'll add some more bars from front-to-rear similar to Boyink's cage, as well as grab bars.
To make the saddle cuts on the tubing, I used an 1 7/8" holesaw. I finally broke it and switched to a 2" which works better - less grinding! I'll try to get more pics tomorrow.

 

That tubing looks to me like HREW (regular old welded seam). DOM won't have a visible weld seam and it has a slight candy cane or barber pole look to it because of how it's made. There's nothing wrong with HREW and it's worlds better than SCH 40 or SCH 80 pipe.

I like the design of the cage. The only thing that would bug me is that the muffler shop didn't use a mandrel bender. That tubing is actually kinked where the bends are made. Technically it isn't as strong as a cage made with mandrel bends, but I'm not going to rip it apart like some other websites would. In my opinion a cage is only supposed to work once; not every time the vehicle is taken off road. Yours looks like it will keep you and your family safe if the worst ever happens. It's miles ahead of running with no cage or just the factory bar and it looks like you're putting tremendous attention to detail in its build. Good luck with the rest of the project.

 

Don-

If you are concerned about the bends, you can always gusset them.

 

Dennis - Yea, if fact, I bought plate just to do that but I'll wait until it's welded up before deciding.
BTW - hope you get to feeling better. Nothing worse than being sick on a day off!
Here's the last of the bars to be installed and a pic of the dash mounted shear plate.

 

Added grab bars (semi-sorta stiffeners to strengthen crush bend). Was planning on grab bars for driver and passenger anyway - ended up with six. More welding /grinding, then primer.

 

That's the ticket right there!

 

Yeah I like the look of the grab bars. Wish I would have installed a couple on my jeep.

 

like it

 

So, *ahem*, Don...how much is the deposit for you to build me one?


j/k...I can only dream.....

 

Well Ron *ahem*, the deposit would only be two bits (half the normal price since it's for you ), but the final payment would be a killer:twisted: !
It's been a real learning experience, for sure. I think the only way I'd ever do another is if I had a bender and did it myself, but that's too much $ up front for one cage. BTW - I talked to a local guy here yesterday that can do manrel bends - story of my life - day late and $ short. R)

After the cage is finished and painted black, what would be a good sealer to use between the body and mounting plates? I'm thinking undercoating - any suggestions? :?

 

Silicone seam filler. comes in a tube use caulk gun, you can get it where you buy your automotive paint...usually.

 

David - thanks. I'll check it out when I buy the paint. I thought about using a combination of dirt, grease, mud, oil - you know - the usual undercoating on a jeep!

 

seems to hold some I've owned together

 

Cool!!! Thanks for the offer! I'll just file that little tidbit away for now, we gots a loooooong time before I'm ready for that. Been many, many moons since I've done any real welding, not that I ever was a "real" weldor. But it'll be fun to do it again.

 

Finally!!!!! Rollcage finished and installed. Next project - seatbelts, tow bar stuff.
#1 - off to powdercoat
#2 - installed
:driving:

 

WOW! Looks good

 

Great looking cage! Good job!
I musta missed all the other pics. Do you have the other pictures still? I would like to see them. especially where the cage attaches. If you don't want to post them again maybe you could e-mail them to me.
tim_springer@trimble.com

 

Awwwwwsome