Homemade RollCage and other words that don't go together

[PDK]

After coveting a custom rollcage for quite some time, I finally decided to just build my own. For the past 2 years, I've been collecting tools and knowledge. I shopped around in our region significantly and twice had someone lined up to do it. I began to realize that I had everything I needed tool-wise and I've been getting better at the metal fab stuff.
Here's the tools that I've been using the most:
Miller 210 welder purchased used last year
Craftsman Drill press from flea market
Hand drill from Lowes
4 1/2" angle grinder from Lowes with plenty of flaps/grinds/cut offs
Pro Tools 105 tube bender: on loan from my cousin, but had to buy the 1 3/4" die.
Ancient chop saw on loan from my cousin
Bend Tech Pro, Bday gift from my dad this year...took me forever to grasp it tho

Surfed a ton of Jeep boards looking for ideas and finally came up with a custom design of my own. I thought this for about a week until I saw the Poly Performance cage Mine has the rear halo like theirs...not much new under the sun, eh?
Here's a pic of a pic of Bendtech:


Finally saved up enough to get my DOM and a bit of 3/16" plate and 1/4" plate for brackets and gussets. I think I ended up buying almost 150 feet of tubing, but I may need more due to several screwed up bends
I also picked up these for the frame tie-ins:

[PDK]

Paul E has been helping me out and we got the A pillars, rear halo, and C pillar legs all bent up yesterday. I finished up my 3rd B pillar last week after screwing up the first 2.



I've also got the floor feet mostly done and some of the under body frame tie in brackets done. This was a bit challenging, but fun nonetheless. Not much can be found about this step, so let me know if you need help with feet/tie-ins. I don't have any pics, so I'll take some and post up later.

[samb.]

Don't toss the wasted tube. Take a sharpie and mark bend locations and degrees and make some samples. so that you know exactly where to place the tube in the bender so that you won't screw up as many pieces next time.


Cage looks good so far though.

[97TJAC]

looks good!

[Paul E]

samb, he's keeping the scrap. Some if it will be easily usable for some of the shorter straight sections he has yet to cut. One piece we messed up we ended up using because we knew exactly how far we bent it.

We got a system going for measurements and how to feed the bender. Once our brains warmed up, we really got going! Whatever he doesn't use on his cage, we may put to use on some other projects, perhaps even some reinforcement on the back of my cage. But the goal is to get HIS cage done and get his jeep out of the garage!!!!

Dave, does it still run? heheh

[john roach]

looks like you got a good start, its looking good

[PDK]

I hope it still runs! LOL!!!!! I didn't get any pics last night, but I did get my bolts for the new Grant steering wheel with quick release and a ton of 1/2" washers for the tie-in's.

[Paul E]

Don't fire ANYTHING up until you have the dash and wheel back together. You'll likely throw codes with the front airbag removed... so may want to check into that if you can.

[PDK]

Yea, thanks. There was a big thread on Pirate about installing this Grant quick release set-up and all that it would entail. It is not suppose to throw any codes....

[PDK]

Well, I haven't had a chance to work on the cage any, but did swing by the steel yard at lunch to pick up a few pieces of scrap. A foot of 2 1/2" square to finish building up the tie-in mounts.....AND a long piece of 3 x 4" box. My Fab ADD is kicking in again.
I've been wanting to do this: http://www.genright.com/ProductInfo....ductid=BMT2001
So, I am going to add that to my list. I had decided to hold off, but felt that the rubber body mounts wouldn't "mix" with the poly cage tie in bushings. I've got the 1 1/4" body lift that sits on top of the factory rubber body mount bushing. Now I need to get some poly body mount bushings and the new steel will cover the lift part.
Anyone need a body lift? ...for cheap