FugginZukin's RZR cage build

[FugginZukin]

Hello All,

My inspiration to build this cage is the fact the stock one is a death trap. To start, the stock mounting pads for the stock roll cage are pathetic at best. I am beefing both front and rear up with some 3/16" steel plate. The rears will be held in place with four grade 8 bolts per corner. The fronts will be welded down.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0463.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0465.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0466.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0468.jpg

[FugginZukin]

Next step was to build the rear hoop. I wanted to maintain the stock lines except utilizing a hoop form.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0474.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0476.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0477.jpg

[FugginZukin]

Next step was working on the front mounting pads.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0484.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0487.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0495.jpg

[FugginZukin]

Forming up the pillars.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0479.jpg

[FugginZukin]

Working up some bracing, coping, and preliminary mock-up.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0507.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0517.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0520.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0521.jpg

These tube clamps will be used in the front to be able to remove the front plastics.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0524.jpg

That's all I have done for now. I will be working on it all weekend and hope to have it completed. More to follow. Let me know if you have any questions.

[FugginZukin]

Built spreaders and some cross bracing this weekend. Cage will drop approx. 3/4" once I cope the bottoms of the cage to fit the mounting pads. Next will be work on the rear cross bracing as well as hooking up the 4 points.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0528.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0530.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0537.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0541.jpg

[Crowdog]

Nice work!

[Jaggedx]

Very nice!

[JW]

Any progression on this? Nice work!

[FugginZukin]

Nice work!

Very nice!

Any progression on this? Nice work!


Thanks guys. I appreciate it!


Had a rough past couple of weeks and wasn't able to do anything on the RZR. I will be putting in some work on it this week/weekend in which I will update the thread. Thanks for the interest.

[1wook]

Nice cage work.

I like your cylinder mount on your bender.

[FugginZukin]

Nice cage work.

I like your cylinder mount on your bender.

Thanks. The cylinder mount is just a 3" piece of pipe cut in half with two pieces of plate with holes for bolts welded to each end of the pipe to form a clamp. Then there is a smaller piece of tube (sleeve) that slides over the outside bolt of the bender that is attached to the 3" clamp. On the arm end there is a piece of tube (sleeve) that goes over the outside bolt of the arm that has an old steel socket that fit over the end of the ram rod welded to it. Wallah, done. I got the idea from OffRoadFabNet.

[FugginZukin]

Finally was able to get some work done on this thing. I apologize for the delay. I have been extremely busy. :shaking:



http://i200.photobucket.com/albums/aa204/1988ToyST/100_0762.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0763.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0767.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0770.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0774.jpg

[FugginZukin]

Got some more work done. Should be finished by Sunday. I'll be putting some paint on it tomorrow.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0776.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0778.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0783.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0786.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0789.jpg

[Crowdog]

Damn. That came out really nice.

Do you do this sort of stuff for a living?

[FugginZukin]

Damn. That came out really nice.

Do you do this sort of stuff for a living?

Thanks man. I really appreciate it.

I wish I did this stuff for a living. :D Nah, I am just a hobbyist who tinkers in the garage once in a while.

[stallion85]

Pretty freakin' sweet! Those are some nice fat welds on those joints. What thickness of tube are you using?

[KS Toy]

VERY nice indeed! Be sure to post up pics when it is painted and installed. How do you like the RZR?

[FugginZukin]

Pretty freakin' sweet! Those are some nice fat welds on those joints. What thickness of tube are you using?

Thanks! The tube is 1 3/4" .095" wall DOM.

VERY nice indeed! Be sure to post up pics when it is painted and installed. How do you like the RZR?

Thank you. I will have some painted and assembled pictures up hopefully by the end of the week.

I like the RZR so far better than other UTVs that I have driven in terms of performance. The power and the ride are great. The one negative I don't like is the build quality. I wasn't too impressed with the stoutness of the frame and overall quality of assembly. Overall I am happy with it however.

[Crowdog]

Well for just a garage guy, you do great work. Please keep the pictures coming.

[shortsub]

that thing looks awesome . really nice job!!

[leeman1790]

Thats some excellent work, looks better then the stocker and of course hell of alot stronger. I'd imagine the frame would fail before the cage haha.

[FugginZukin]

Well for just a garage guy, you do great work. Please keep the pictures coming.

Thanks! Some new pics on the way.

that thing looks awesome . really nice job!!

Thank you.

Thats some excellent work, looks better then the stocker and of course hell of alot stronger. I'd imagine the frame would fail before the cage haha.


Thanks. I agree, the frame would definitely fail before the cage. I have considered making a sub-frame to attach to the cage for the seats to bolt to. I kina feel uneasy having the lap belts attaching to the toothpick frame and the shoulder harnesses mounted to the cage. Maybe I will do that mod down the road.

[FugginZukin]

Needed a way to attach the side/net bars to the cage, so I cut off the old mounts from the stock cage and welded to the new.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0791.jpg

Got some paint on it over the past few days and have gotten the cage bolted to the RZR. I used Rustoleum black "hammered". It turned out pretty well. It is more of a dark gray than a black however. Matched the seats and plastic pretty good. Overall I am happy.

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0801.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0804.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0805.jpg

http://i200.photobucket.com/albums/aa204/1988ToyST/100_0809.jpg


Next I will be making the harness mounts and a spare tire carrier that I had been planning to make. I will post those in this thread as well. I won't be active for the next week or so due to moving back to Arizona. Take it easy!

[KS Toy]

Looks GREAT! Can't wait to see it with the 6" lift and 32" tires! :evil:

[Todd W]

damn, that is a tank now, 1 3/4 is more than I used in a bunch of places on my buggy :eek:

Looks awesome, great work :) Roll it!! the mounts should holdn ow too, tweaking th eframe I guess is your concern ;)

[stallion85]

Looks great all painted up! Cool design in your cage, good job!