Well, I've gotten a bit of a start on my K30 buggy body/cage. But I've got a few questions. Recent pics are attached with modifications that indicate where some of the future pieces go.

1) In the attached image, do you think the red bar is needed to stabilize the main hoop? It will make getting in and out a PIA so I would rather avoid that. Currently, I'm planning on putting it in with a slight bend to match the shoulder bend in the main and forward risers. I know it would not be as strong but, maybe if I also went more verticle at the top, and angled more forward at the bend (following the side of the seat basically) it would provide enough support as a compromise? Also, I'm wondering if the lower extension to the rocker tube is really needed? Ideas?

2) I need body mounts at the rear for the blue bars (and the other bars that will feed off them). I have a set of GM body mounts, but they require a 2.250" hole. I can't build a cross member there, because that is where the gas tank goes. Putting a bracket on the outside will be a pain due to suspension brackets already there. So, I want to just put it on the top of the frame rail. Only problem is the 2"+ hole would weaken it too much. I was thinking maybe body mounts from an older CJ7 or something. Maybe I'll just build a bracket for the cage/body and mount the GM bushings in it, then I'll only need a 5/8" hole to pass the bolt through the frame. Suggestions?

3) In the second pic, notice the arrow at the front of the cage, where the a-pillar risers intersect the forward halo. The forward hoop extends over the windshield frame to offer some small protection there. I expect the windshield will probably still get busted in the first roll over but, what the heck. If it does, I’ll cut the windshield frame out and replace with a folding jeep/hummer style flat frame and window. Anyway, The halo will be “X”ed, crossing at the main hoop center. I’m wondering if I should add another cross bar at the red arrow. Bent a bit at the ends to follow the roof line AND the top of the main hoop. It would look sort of like a front hoop style meets halo style. Then the “X” would lead to that “front hoop” top, with a pair of extensions leading out to the brow to help keep it from folding down. BTW, there will be a pair of 1” x 0.125” gussets (blue line) supporting the brow on the ends. Is this just wasting time and adding weight? Should I just extend the “X” to the “brow” and call it done?

Any input on any part of the cage would be appreciated.

http://www.members.cox.net/russhuffman/cage/partial1b.jpg
http://www.members.cox.net/russhuffman/cage/side1b.jpg

I don't think you need that red bar.I would have put that lower bar going from the front hoop to the rear hoop at angle.I would ran it from the rear hoop at just below armpit level at an angle down the rocker tube.Would be easier to get in and out of and give you something to lean on.Also why not use a leave spring style bushing to mount the blue bar to the frame?Blazin:rasta:

I considered running the bar like you suggest. And I may yet, that horizontal brace is just spotted on there.

I didn't want to use the spring bushing type mount because I wanted more movement in the mount, like the factory mounts used for the front portion of the cage.

in the windshield pic you might make the brace a little longer and move it in farther for a little more support( would also keep the branches farther away from the winshield). had you thought about tubing the whole rear section? thats always a fun way to go.:D

Originally posted by FULLSIZE
in the windshield pic you might make the brace a little longer and move it in farther for a little more support( would also keep the branches farther away from the winshield). had you thought about tubing the whole rear section? thats always a fun way to go.:D
Not sure I follow you on the moving the brace. Are you saying move the halo end of the brace further out onto the brow? The bar is pretty tight to the body there, and the a-pillar riser is actually set into (what was) the door opening. The outside of the bar sticks only about 1/4" beyond the edge of the windshield frame for most of the length. There is more at the top, but not enough to do what I think your suggesting. I have notched the windshield frame a bit to make room for the brace. It is a little longer and further forward than the chop indicates, but not by a lot.

As for tubing the rear, that's my plan. It will have a rear cargo area and room for a rear seat. The rear opening (behind the front "door") is for access to the back seat. Here are some pics of the cage model I posted a while back but didn’t get much feedback on. I made the model because this is my first cage, and I wanted to see how it would go together better than what I could see on paper. The design has changed a bit while building, but it’s still basically the same idea.
http://www.members.cox.net/russhuffman/cage/cagemodel1.jpg
http://www.members.cox.net/russhuffman/cage/cagemodel2.jpg
http://www.members.cox.net/russhuffman/cage/cagemodel3.jpg