TJ Holeproof cage install

[naturalbornmudder]

This thread is to document the cage install on my TJ.

GETTING NAKED:
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/DSCF0007_001.sized.jpg
We started by measuring and notching a piece of DOM that would serve as the front top spreader bar. Adding this gives more compression strength to the entire existing cage so that in case of a sideways roll over, the cage would not collapse internally.
NOTCHING:
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/DSCF0006_001.sized.jpg
WHAT WE ARE KEEPING:
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/DSCF0009_001.sized.jpg
We are going to use the existing overhead hoop and down bars at the rear of the cab but the 33" front overhead bars near the drivers and passenger's head were weak and needed to come out. I wanted to maintain the ability to flip the windshield down, so we lobbed off the end of the OEM bars so we can re-weld the foot end onto the DOM tube we are using to replace it all with.
NEW OVERHEAD D&P BARS:
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/DSCF0012_001.sized.jpg

I'll keep you updated as things happen.

[crazy4ink]

Very cool man! Nice to see you making a start on this! Is the bar from the center hoop to the windshield going to bolt to the windshield?

[naturalbornmudder]

yes, using the old foot ends from the original bars. I'll be able to fold down the windshield the same way as before.

[crazy4ink]

So, how are you planning on running the downtubes in the front? Are you still planning on running the downtubes through the dash?

[naturalbornmudder]

yes, we are going down through the dash, moving the vent hoses to one side, and once they go through tot bottom of the dash, we'll angle them back un under the dash and down to a plate on the floor. Then sandwich the body with another plate from the frame up.

[crazy4ink]

Sounds like you guys have a good plan for everything! Can't wait to see the final product!

[sevenslats]

Nate/Eric, Stop by my house, and Ask Julie for the TOR cage instructions. I'll let her know you're coming.

You can't "move the vent hoses to the side". They're rigid plastic. My kit came with flexible duct, to replace the OEM stytuff. It's the same as plastic dryer exhaust, but rectangular. plus mine had bling clamps on the ends to keep it air tight. HD or Lowes may have something that would work.

My windshield is only attached at the bottom. I've driven plenty topless, and never had a problem. Also, I've pulled the softtop tight, and it only attaches at the top of the windshield. again, no adverse effects. Your call.

[naturalbornmudder]

Geoff,
I will surely drop by and grab the instructions.

Tongiht was another successful night of fabbing. We took off the doors, hard top, neoprene seat covers, and flipped down the windshield.

We got the OEM feet welded on to the new DOM "overhead" tube bars(in picture #4). Thanks to Geoff's old OEM bars in the corner of Eric's garage, we had a piece long enough to make it work. Next we levelled the overhead bars and tacked them in. We are weary of fully welding them until we get the spreader bar fit and the front to center bars fitted too.
Eric pre-made the rear spreader bar after I left last night so we will probably get it welded in tomorrow night.

We took prt of the dash apart to find what sevenslats had said; the heater duct is not too flexible so we are either going to have to cut through it or get some other ducting to run around the tube.

Eric and I worked and talked at length during all of this and decided to go ahead and go the extra mile and put in some driver and passenger door protectors that run from the center bar to the floorboard where the uprights come down from under the dash at a 45* angle.

Sorry fellas, no pics of tonight, but man it looks cool to see the heep with the windshield down and the top and doors off. ;D

[holeski]

Geoff, thanks I’ll try to stop by on Monday. What is a good time to run by? Nate I cut the holes in your dash as you where driving off. I didn’t'’ what to see you cry as I cut into your dash. +I farted around today, more trying to clean up so I could find tools and move around. We removed the hard top and that made everything easier to work around. I would be getting more done if I didn’t need to get the J-10 running ASAP.

[sevenslats]

Call Julie to see when is good. Also, feel free to scope out my cage,dash. The TJ is sitting in the driveway.

[holeski]

Hey sorry, I was hoping to bust most of the cage out today but, we where having some mods done to the house and the workers needed to put a bunch of stuff in the shop. We had 10” of insulation blown in the attic to help battle the cold. I did get out there for a bit and knocked out the rear spreader. Need to double-check the hard top clearance and I’ll weld it in tomorrow, then do the front down bars.

[4x4_MMMH_4x4]

just noticed your sig nate... i hate chuck norris, f$#$#%# chuck norris >:(

rofl

[TJVigilante]

just noticed your sig nate... i hate chuck norris, f$#$#%# chuck norris >:(

rofl


Quoted for Truth. Every time I see his fat head on my TV I want to roundhouse kick it into the neighbor's yard.

Anyway, why are you keeping the rear bars? I guess they're strong enough? You run around with the little ones every now and then, hope they can handle it. I really don't see why not though. Looks pretty good from here.

[LowNSlowNeon]

just noticed your sig nate... i hate chuck norris, f$#$#%# chuck norris >:(

rofl


you know chuck norris doesn't dodge bullets.....bullets dodge chuck norris.

[naturalbornmudder]

When he jumps into the water, Chuck Norris doesn't get wet, the water gets "Chuck Norris"

[naturalbornmudder]

When the Boogeyman goes to sleep every night he checks his closet for Chuck Norris.

[holeski]

Now NBM you where the one just complaining about off topic posts and how you had to delete a bunch, now look at you. Anyway what are you up to tonight. I’m going to get a few of these bars in then I’ll need your but over here to check the clearance between the center bars and your planetoid head. See Nate is a big guy, and you don’t really notice it until you see him in a TJ. But his head almost sticks out above the cage, so we can’t put the bars directly over or even too close to his head with out making the hard top obsolete. Maybe we should cut holes out of the top and insert clear bowls for you head so you can see out over the top. Man I’m just messing with you. ;D

[STOMPR]

ROFL ....I could totally see Nate driving around with a clear dome sticking out of the top his head looking around with his ape arm hanging out the window, draggin knuckles on the ground LOL the visual is killin me LOL

[holeski]

;) Oh thats bad. Nate we love you man. :angel:

[4x4_MMMH_4x4]

ROFL!!! just drop his seats down a bit... :D or maybe we can chop off some of the legs... short legs, long arms, APEMAN...
but on topic i cant wait to see some more pics of this badboy

[ChevyKev]

Maybe we should cut holes out of the top and insert clear bowls for you head so you can see out over the top.

::) I saw Red Green once make a sunroof out of an old fish aquarium....

[michaeljr5]

Grape Ape! Grape Ape! ;D

[LowNSlowNeon]

ROFL ....I could totally see Nate driving around with a clear dome sticking out of the top his head looking around with his ape arm hanging out the window, draggin knuckles on the ground LOL the visual is killin me LOL



CLASSIC....hahahaha

[holeski]

OK, back on topic! I have the rear spreader bar welded in. Heather and I put the hard top on after I fitted and tacked it in place. Everything clears and the rear window opens without any interference. I cut and am welding in the rear cross bars now. I had to stop and let my welder cool down; it has the wrest duty cycle. After I get those all welded up I’ll start the front down bars. The front spreader needs to be re-notched to fit with the larger sidebars we put in.

[naturalbornmudder]

talking with Eric, he is pretty close to being done. I have not been over to help him out since the broken foot incident. We are adding some side seat protection bars soon.

[LowNSlowNeon]

Sounds friggen nice? Wheres the progress pics?



OT: I drove by holeskis house the other day on accident.. just driving around and exploring.

Nice place man. :P

[holeski]

Thanks, you should have stoped in and seen the cage. I have why to much stuff out front.

[LowNSlowNeon]

Thanks, you should have stoped in and seen the cage. I have why to much stuff out front.


woulda been weird.. oh hey man I was uh just driving around.. whats up :P lol

[mousee]

Thanks, you should have stoped in and seen the cage. I have why to much stuff out front.


woulda been weird.. oh hey man I was uh just driving around.. whats up :P lol


no, I am not stalking you... really...


LOL :D

[holeski]

No really there are people not even on this site that just stop by.

The cage is almost done. Yeah I had baby duty all day today, so it was him, me and the PS2. Nate stooped by last night with his limp foot and we went over a few things. Sorry no pics. My camera is broke, NBM’s computer is broke and his camera won’t work with my computer. Cages are fun and I have learned a lot. Like TJ’s suck, they are just so small inside. Anyway, we had to change the way the overhead bars where going in to clear Nate's head and I added some 1.5” gussets in a few spots. My welder has a duty cycle of like 3 so I have to keep stopping and wait for it to cool down. I’m getting a new welder and plasma cutter here real soon, that and adding a work shop behind my garage to fit the bender and some of my other bulky tools in. Then next summer we will try and get the slab poured for the shop. That way things should move much smoother. Nate seem real happy although his windshild crack spread some with us putting the cawl up and down. He has wants to paint is so I will be leaving it unpainted.

[michaeljr5]

Here are the pics of NBM's cage install thus far:

http://www.arcticoffroad.com/gallery2/main.php?g2_view=core.ShowItem&g2_itemId=8693&g2_navId=x45314dd8

[AKLJ8]

The cage looks great guys!

[crazy4ink]

Looks awesome Eric! Great work on the cage man!!

[holeski]

Thanks. It’s done, just a bit of cleaning up to do. The door bars didn’t work out with the full TJ hard doors. There are a few things I would do different now looking back. The front down bars, instead of drilling a hole in the dash I would move the tube further back and just notch the dash. Small stuff like that. I talked to Nate and I think what we will do is tie the down bars mounts into his rocker guards, which will spread the weight if rolled though out the rockers mounts also. We can’t go to the frame with the rocker guards in place
I have fond a major flaw in my house. I blow the breaker every 5 min or so. Need to fix that before e I start the next job.

[sevenslats]

Looks ++++ nice.
Did you run a bead around the adjustment seam on the b-hoop? YJs are one solid piece, TJs unbolt and become 3 pieces. I had mine welded together when my cage was installed.

[holeski]

We had talked about it, but decided to let it be for now and see if it settles into place. Nate’s Jeep was in two major accidents before he bought it and lets just say that not everything is straight. That went for the stock roll bars too. I did my best to make it as even as possible. Bars that I made exactly the same had very different placements. It took two big ratchet straps and a high-Lift to get everything into place. So I’ll give it some time to adjust itself to my new permanent brace then I’ll do it.

[naturalbornmudder]

WooHoo! The cage is done. Now all I gotta do is get the top and doors back on, and the seat covers back on and I'll be ready to bring her home.

[sevenslats]

What did you end up doing with the heater vents?

[4x4_MMMH_4x4]

and heal that foot up buddy :D

[holeski]

What did you end up doing with the heater vents?

Nothing yet, they didn't work right to start with. We still need to pick up the paper work from your house.

[naturalbornmudder]

lil' T is back home as of last night! The cage looks great! A few final touches and that will be all. The docs say I will be able to drive Monday, so I will be sporting the new cage very soon.

[LowNSlowNeon]

lil' T is back home as of last night! The cage looks great! A few final touches and that will be all. The docs say I will be able to drive Monday, so I will be sporting the new cage very soon.


Quit using yer foot old man! >:(

[sevenslats]

We want some full-view shots. like, the entire vehicle, cage and all.

[naturalbornmudder]

when it gets warmer a few degrees, I'll take the top off and take pics frm outside.

It is currently -50 so I won't be doing anything till it warms up 30 degrees. ;)

[crazy4ink]

Looks really great Eric! Great idea to tie them into Nate's existing rocker guards too. Shame the door bars didn't work out though, they look really good. Can't wait to see the full pics!

[holeski]

We couldn’t go to the frame with those rocker guards in place; the bottom of the floor pan isn’t flat on a TJ so we could sandwich it with plate. Now that Nate has sold the rockers we can mount to the frame. I still what to put some gussets in down the road. We’ll see what Nate what to add later.

[crazy4ink]

So, you guys just going to fab another set of rocker guards at a later time?

[naturalbornmudder]

yes, we are going to do some ones out of tube.

[naturalbornmudder]

I got the last gussets and cross braces put in now, so it is just a matter of finishing up the welds all the way around. I measured3 or 4 times to make sure the medicine wasnt messing with me, and welded em up.

Thanks to Michael for coming over and helping with the hard top

[sevenslats]

:nopics:


That is so easy to say when it's +36* outside.

[michaeljr5]

That is so easy to say when it's +36* outside.


Having a heat wave, how are you coping? ;D

[sevenslats]

Actually, it feels real cold. It's much more humid, and the wind is a killer. I was surprised to see that the cold weather bag was a requirement on my orders.

[Buckeye]

When I was in Iraq we were there with some guys from Nellis, they were issued the the white bunny boots and one guy actually brought them with him. I didnt get those boots when I got here.

Anyway

Cant wait to see the picture of the cage, A cage is on my list of upgrades for my jeep.

[naturalbornmudder]

here are a couple of updated pics. The only thing left is to primer and paint it.
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/Picture_001.sized.jpg
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/Picture_003.sized.jpg

[crazy4ink]

Looking really good man! That thing looks like you could pick Lil 'T up by it.

Painting all that tube is going to be a challenge though. Wish I was there to helpout man!

[naturalbornmudder]

I plan on painting each tube individy=ually so I don't get paint on the jeep. Looking back, I should have primered and painted the thing before we installed it and then just repainted the weld portions. Oh well, the next guy can learn from my mistake.

[sevenslats]

I attempted to paint the tue beforehand, then do touch-up after weld. but I tried to paint at 35*, and it still looks like crap.

[michaeljr5]

Nate, give me a call if you need help painting or whatever.

Quick thought on the side bars by the seats. You know you could always make a bolt ons. So you can take them in and out depending on if you have your doors on or off. Just a thought.

[LowNSlowNeon]

wrd nate - give me a ring if ya need anything.

PS: I never got your PM from the members forum :P

[holeski]

When are we going to see photos of this thing painted?

[naturalbornmudder]

Well, I held out for a while on the painting but it is finally done. I am very pleased with the outcome too. It looks like a totally different jeep with the cage painted.
http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/painted_cage_004.sized.jpg

http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/painted_cage_003.sized.jpg

[holeski]

That looks cool I want one.

[sevenslats]

Wow that's a lot of tube. Great work.

[naturalbornmudder]

http://www.jeeps-offroad.com/reader-rigs/albums/NBM-family-Jeep-photo-album/painted_cage_008.sized.jpg