I whipped this build together for a buddy (Mike). He happens to volunteer as park staff at Rausch Creek, so those of you who visit there keep an eye out.

He wanted me to swap the minitruck axles in, and build a "simple" 6 point cage. Well, I don't do stuff the simple way, I do it the right way. Here's what I came up with.

Out with the old:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1713Medium2.jpg

Getting a little idea of what it'll look like when he buys my old 36s.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1714Medium.jpg

Rear axle gets some pipe cap protection.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1722Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1723Medium.jpg

Then I picked up some 1.75x.120 DOM

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1728Medium.jpg

and started getting an idea of what I want to do with the A pillar

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1729Medium.jpg

The next day I got the A pillars in and started playing with door bar ideas. I didn't really like this one.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1732Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1733Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1734Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1736Medium.jpg

Windshield bar

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1739Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1742Medium.jpg

For the rear I was having trouble figuring out an easy way to tie to the frame. Instead I went a little in depth (out the window goes that simple cage idea) and came up with this...

A hole

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1746Medium.jpg

A little bracket and some welding

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1745Medium.jpg

Slides right in

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1747Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1748Medium.jpg

Then the base plate gets welded in, tapped to M10 thread, and a matching top plate gets bolted in place to accept the tube.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1752Medium.jpg

That tube that went in the quarter panel goes all the way down and ties in here

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1753Medium.jpg

Overall of the down tubes

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1749Medium.jpg

Center roof bar

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1754Medium.jpg

Dash bar sits nice and tight

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1755Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1758Medium.jpg

So tight in fact that i broke his windshield putting it in

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1759Medium.jpg

Next day's progress...

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1761Medium.jpg

Gave him some broad shoulders. I love this look.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1762Medium.jpg

Harness mounts

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1763Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1764Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1779Medium.jpg

Overall progress. Yea I take lots of pics. :flipoff2:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1766Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1767Medium.jpg

New door bars in place.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1768Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1772Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1781Medium.jpg

Since the windshield was cracked, Mike told me to just ditch it.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1784Medium.jpg

The front 8" got armored and installed as well.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1787Medium.jpg

I used some stock XJ spring plates with some redrilling to give a little stretch.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1791Medium.jpg

Rear tie ins welded up

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1793Medium.jpg

Overhead progress

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1794Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1795Medium.jpg

Then I pulled the cage to do final welding and fit the last three tubes.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1796Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1797Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1798Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1799Medium.jpg

Speaking of welding, how bout some bead pics.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1801Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1803Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1804Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1806Medium.jpg

Added roof bars

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1808Medium.jpg

Made more pretty beads.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1812Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1816Medium.jpg

I didn't like how the harness bars had a void between them. I couldn't bring myself to run a straight bar, so I put this in. I think it looks real nice.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1817Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1818Medium.jpg

Laying down a little paint so Mike can pick between red and black.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1819Medium.jpg

Then I got started on the other 4 frame tie ins. This is the B pillar.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1820Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1829Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1824Medium.jpg

At first we were thinking black, so I added more black primer...

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1831Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1832Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1833Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1837Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1838Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1840Medium.jpg

Pile of junk

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1839Medium.jpg

A pillars needed some bracing to reach the tie ins

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1841Medium.jpg

Tractor implement red, 5 coats. :smokin:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1842Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1843Medium.jpg

Final suspension stance. 3" total stretch. Those are 33s. My 36s will go on when he gets some 17" rims.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1844Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1845Medium.jpg

Rear all done up pretty.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1846Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1848Medium.jpg

Shaft in place. Needs about 1" added to it.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1849Medium.jpg

Before paint I added some grab handles and a windshield V. While it was drying I decided to fab up a cowl cover for the exposed dash. When you take the windshield off it leaves an ugly look, like this:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1850Medium.jpg

After:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1851Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1852Medium.jpg

Really cleans things up

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1854Medium.jpg


Final assembly. All done.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1863Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1862Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1864Medium.jpg

RC staff :p

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1865Medium.jpg

:smokin:

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1866Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1867Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1868Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1869Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1871Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1872Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1873Medium.jpg

Top to bottom. You hardly even notice it.

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1874Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1875Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1879Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1881Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1882Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1884Medium.jpg

http://i74.photobucket.com/albums/i273/Timmay822/Mikes%20Sami/IMG_1887Medium.jpg


That's all I got. Mike just needs to add a hi steer kit, do up some brake lines, and get the proper lug nuts. If you all have any questions let me know. :D

that looks real good but why the hell did you keep the stock hoop????also i love the back frame mount

How much shipped to 47150? :D

why not notch the axle caps for the fill plug and for drainage?

Great work man, love the cage work. The Pipe caps I am not fond of though, too much friggin mud up here! Cannot wait to see her with the 36's.

that looks real good but why the hell did you keep the stock hoop????also i love the back frame mount

That's what Mike wanted. Customers are always right. :D

why not notch the axle caps for the fill plug and for drainage?

They have 5/8" holes on the bottom, you cant see them. I could fit a socket on the fill plug without an issue. It must be a bad angle.

Make sure you post up more pics of the harness install I have the exact same ones and I'm working out the details of that right now in a similar rig. I'm guessing by the shoulder height that you picked behind the seat that the person you are building it for is taller than my little short ass:laughing:

That looks :smokin: I like the way you tyed the rear in! I'm going to start my cage soon and might do the same thing.

Make sure you post up more pics of the harness install I have the exact same ones and I'm working out the details of that right now in a similar rig. I'm guessing by the shoulder height that you picked behind the seat that the person you are building it for is taller than my little short ass:laughing:


Yea, he's about 6'. I'm at 6'2" or so and I set the harnesses so that they come at a 10* angle up to my shoulders. Simpson recommends 0-10* at your shoulders, so him being shorter than me should land him right around 5-8* or so. Perfect.

The rest of it just ties in to the stock seatbelt brackets with some adapter plates. Pretty simple.

That looks :smokin: I like the way you tyed the rear in! I'm going to start my cage soon and might do the same thing.

:) One thing I wish I did was french the 1/4" plate into the body. Then you wouldn't even notice it was anything other than the body with some holes tapped in the top.

Either way it's clean, that just adds some pimp factor.

Thats a sweet cage, It really nice to see some good tech going on in this forum. What kind of bender did u use, and how did you get the tight bends in the dash bar.

I liked the first set of door bars. They looked easy to get in and out, why the change?

Is that on Rt 38?

Very nice work and great welding! :grinpimp: I understand the what the customer wants part, but in reguards to the stock hoop, I would have added some gussets from the DOM to it to spread out those loads more on the thinner tube of the stock bar.

Now just needs to clean up the rest of the zuk to make it match that nice cage! :D

nice....shit looks really good as usual....

Man, I wouldn't ride in that thing for any ammount of money!

At least while those :rainbow: blue marker lights were still on there :flipoff2:



Seriously tho, looks really nice. About how much you think the cage added in weight?

awsome work. Some killer ideas and craftsmanship in that cage.

Thats a sweet cage, It really nice to see some good tech going on in this forum. What kind of bender did u use, and how did you get the tight bends in the dash bar.

I use a homemade bender that runs pro tools dies. The dash bar bends were done with a 5.5 CLR die. It worked well.

I liked the first set of door bars. They looked easy to get in and out, why the change?

I didn't think they flowed with any other part of the cage. They did make it easy to get in but I just didn't like them.

Is that on Rt 38?

:eek: Actually it is. Did you drive by and see the sami outside or something?


Very nice work and great welding! :grinpimp: I understand the what the customer wants part, but in reguards to the stock hoop, I would have added some gussets from the DOM to it to spread out those loads more on the thinner tube of the stock bar.

Now just needs to clean up the rest of the zuk to make it match that nice cage! :D

That's a good call. I thought long and hard about making this this strong. Then I realized I could pick the zuk up at the rear bumper by myself. I probably could've made the whole thing out of .095" wall and been fine.

nice....shit looks really good as usual....

Thanks man. After looking at some Crozet pics I will definitely be down for making a trip. I'll let you know when your lady can make us some dinner. :smokin:

About how much you think the cage added in weight?

I wanna say it weighed about 250 lbs. I had a hard time lifting it by myself.

But remember, he ditched the windshield, doors, top and b pillar. That's probably close to 200 lbs right there. So not much added weight.

awsome work. Some killer ideas and craftsmanship in that cage.

Thanks. I try to do things a little different.

I recognized the shop my buddy used to rent it

I recognized the shop my buddy used to rent it


:eek: That is weird as hell. Cool though. I can't wait to get out of this place and into something a little better.

I think its a pretty cool spot the rent is cheap (at least it was), it seems like you are getting alot done there.

Very nice tube work and welds. Nice to see a nice short buildup like this.

doors off a tintop are about 60lbs each
the sheetmetal doesn't weight much

I think its a pretty cool spot the rent is cheap (at least it was), it seems like you are getting alot done there.

The rent has gone up i'm sure. The biggest issue is we have two 22' trailers, and storing them there has been quite a hassle. Especially trying to back into the driveway at rush hour.

Very nice tube work and welds. Nice to see a nice short buildup like this.

Thanks, I like to sum my builds up in one shot for Pirate. It keeps the bump nazis off my back. :D

doors off a tintop are about 60lbs each
the sheetmetal doesn't weight much

True. The glass is quite heavy though.

nice.

How do you get your notch's to fit perfect every time?????

have to say nice welds and i love the detail in the corners

nice.

How do you get your notch's to fit perfect every time?????

Guess that's just practice.

have to say nice welds and i love the detail in the corners

Thanks. :smokin:

nice welds boss.... :smokin:

ma that little truck put my club to shame when it walked up our competition course at RC. i cant wait to see what he tries now that hes safe in the event of a roll!!

some serious nice work. was this just helping out a friend or do you take these projects on for cash?

got any pics how the a-pillars tied in under the floor?


nice work!

was this just helping out a friend or do you take these projects on for cash?

Both. :smokin:

got any pics how the a-pillars tied in under the floor?


nice work!

Hmm I thought I posted some up. I'll see if I can find them for you.

What size tubing did you use? It looks like 1.75 and a couple thinner peices for the window v bars and handles.

you are correct on the Tubing.

Very nice work:grinpimp: I hope my cage turns out at least half as nice. Alot of nice details.

Looks great the front end looks like it needs some attention. Tube fenders, stinger i think would finish it off. IMO

Its hard to make a cage both safe and pretty you pulled it off well. Almost looks too nice to roll:laughing: