RZR Resurrection

[Bushwhacker]

Thought I'd start a buildup thread since there was some interest in the cage build we are doing. Probably wont be working on it again until Monday due to the holiday.


The damage from doing doughnuts. It pushed the cage over, tweaked the mounting pads for the cage some, and tore the plastic behind the drivers seat. We will be plating over the stock mounting pads to beef them up and using some new ID tube clamps to keep the cage removable. New tubing is 1 3/4" .095 DOM.

http://inlinethumb31.webshots.com/30046/2408693130046050694S600x600Q85.jpg

RZR Tear down...The cheezy thin wall tube bars next to the seat will be rebuilt with 1" tube also.
http://inlinethumb20.webshots.com/29651/2373748530046050694S600x600Q85.jpg

This is how the stock cage should have been built. The owner opted for a new DOM cage versus heavy duty duct tape on the factory cage. :flipoff2:

http://inlinethumb45.webshots.com/31148/2910217120046050694S600x600Q85.jpg
http://inlinethumb17.webshots.com/29008/2502523030046050694S600x600Q85.jpg


New tube being mocked up
http://inlinethumb05.webshots.com/31556/2284285960046050694S600x600Q85.jpg

Front of RZR and all the boats crammed into the other storage spots at the shop.
http://inlinethumb36.webshots.com/30563/2222508020046050694S600x600Q85.jpg

[newimage]

WE need more pics!!!! Love the mock up with Duct tape will be doing a similar Build soon want to protect the wife and daughter.and most of all ME! Chad from Hunsaker Seats is getting me their 4 point harness and might give up the RZR for a few weeks so they can mock up aftermarket seats with.... get this ADJUSTABLE sliders!! to keep the wife happy shes only 5' on a good day.

[mtnbkrmatt]

pics will come tomorrow, assuming Bush remembers to bring his camera......

[Bushwhacker]

Got some more work done on the RZR this week. The majority of the cage is done, except for a dash bar and some side bars to replace the flimsy stock ones.

The factory frame mounts were plated over with 3/16" plate. The fronts are welded on and the rear plates are bolted on. The front legs will have an ID tube clamp welded on for easy removal.

http://inlinethumb32.webshots.com/31135/2748357640046050694S600x600Q85.jpg
http://inlinethumb55.webshots.com/34294/2224220160046050694S600x600Q85.jpg
http://inlinethumb53.webshots.com/31412/2453553400046050694S600x600Q85.jpg


Rear shot with harness bar and diagonal support bar.
http://inlinethumb34.webshots.com/32161/2184470590046050694S600x600Q85.jpg

http://inlinethumb11.webshots.com/31178/2078528360046050694S600x600Q85.jpg

Once I get the tube clamps in, we'll add the dash bar. The tube clamps will allow the front dash/hood to be pulled off, and will be welded in just above where the legs go into the dash.

These are the tube clamps we are using. Much stronger than the factory ones that were butt welded to the thin wall tube.


http://inlinethumb15.webshots.com/32654/2918912810046050694S600x600Q85.jpg

http://inlinethumb63.webshots.com/31294/2583997640046050694S600x600Q85.jpg

Top shot of the spreaders.
http://inlinethumb04.webshots.com/30979/2383059250046050694S600x600Q85.jpg

[wngrog]

Looking good. I love those things, but my kids ride in the back of my Rhino so I ended up ordering a new Rhino instead of gettting a RZR. That RZR is killer though. Took my buddies out to the Hammers with us this year and it was increadible in the desert.

[howyadoin]

Looks great...just remember...always roll left!:grinpimp:

[Bushwhacker]

Got the majority of the cage welded up this week. Gotta install the other tube clamp, dash bar, and bolt it in. The owner came by to check it out and now wants some tube 1/2 doors. :smokin:

Will have some more pics this weekend.

[RoCkSkuLLz]

nice looking cage so far

[Bushwhacker]

Few more pics. We'll have it welded up and painted this weekend and will have some of the final install. Might be taking it up to Hannibal Rocks next week. The owner of the park said that one of the UTV magazines wants to do a side by side comparison at the park and they wanted to see the cage I built.

Next project will be some tube doors to hold the passengers in.


This is the front foot plate below the removable tube clamp, beveled for welding.

http://inlinethumb24.webshots.com/33367/2951883960046050694S600x600Q85.jpg

Cage clamps welded in.

http://inlinethumb11.webshots.com/36170/2032564160046050694S600x600Q85.jpg

Rear legs welded up.

http://inlinethumb26.webshots.com/35609/2227434290046050694S600x600Q85.jpg


Whole cage is tig welded.

http://inlinethumb57.webshots.com/34424/2729881460046050694S600x600Q85.jpg

[Shoope1]

Nice.

I know that the aftermarket cages is way better, but kind of sucks when you wanna get an enclosure.

[silversuper]

hey i was wondering where you got those cage clamps?
i want to try using something similar for fender bars

[LSRGreg]

those clamps are available from Poly Perf, SDHQ motorsports, Camburg offroad.. and probably a thousand other places...

g-