Here is the new full cage… I used the SCCA rule book for the basic design, then used ideas off, about 8 different cages that I have seen out there. For me this is the best set up for performance and general use, with out over building and adding extra weight up top. The new Specialty top just clears it, the bows can even fold down (hence the two bends in the back two pillars) and a hard top will fit over it just fine. (However I don’t plan on using a hard top anymore, in fact I sold off the one I had!) I had to do the final weld up and toss on some paint since I needed it done for our clubs big event a week ago. I will be going back and be adding side bars for the driver and passenger and a custom diagonal support for the “A” (main) bar. I reproduced the stock seat belt mounts so I could keep the stock three point belts for general running about. The four point 3” harnesses will connect to a lower support once I have time to put them in. I machined mounting points for both 5lbs fire extinguishers, so they are no longer hose clamped to the cage. (much cleaner!)

Grab handles and driver passenger clearance

Originally posted by helocat
with out over building and adding extra weight up top. )
:eek: :eek:

Over-built? NOOOO...come on...

looks killer. And if nothing else..is well gussetted:D :D

Nice work.:beer:

One more of the whole thing...

Looks good man!

How hard were the bends to do in the front?

Calculating them out was no problem thanks to MicroStaion’s CAD solid modeling capability. Setting up the bends were a bit tricky and learning how to repeat them even more tricky. I have it down now and can repeat the bends, to make the pillars no problem. (Helps having the engineering drawings and six pages of notes!) I also have a big bucket of scrap bends and left over chunks from the learning curve; let’s just say it was a bit pricy to get it down, tube ain’t cheep! But I got exactly what I wanted, something that fits tight to the contours of the dash and windshield yet still qualifies to the SCCA rule book basic qualifications regarding degrees of bend per tube run.

Rabid: Ya the top gusseting will long out live the six pillars. Over the driver and passenger I wanted metal protecting them from stuff coming through the cage, as well as cutting down on twisting in a violent roll over. At first the thing was going to look like something out of a NASCAR, but I recognized I want to still use the rig for other things and not haul around a 300lbs cage!

Now to finish up the lateral supports…


BTW: Eric D. Nice avitar cruiser shot of Hog’s back! Now I thought you where a mini truck guy? Are you going up for the Flat Broke Poker run this month?

PERFECT!!!

:smokin: :smokin:

When can I pick mine up?

Looks sweeeet

I dig the curv around the dash with the low grabs

Nice! :beer:

Very nice, Mark!

I love it!!

No dashboard crossbar?

Mmmmm beefy :)

looks good :D

SSSSSSWWWWWWWEEEEEEEETTTTTTTTTTT!!!!!!!!!!!!!!!!
Butch:D :D :D

So are you coming down to Texas this month or next to build mine?:flipoff2: :smokin:

Joseph A.

thats a fine loookin cage there, i like the gray paint instead of the usual black.

I love that cage! The design is just cool and diffrent. Sweet glossy grey color ;) :)

I like it! I really like the grab bars too!

I like it verry clean. The dash part is especially trick.

What kind of bender did you use, some of those look really close together.

Ian-

Very nice work. Is it tied into the frame, or only on the body?

how much would you do one of those for....seriously.

-Max

Thanks guys! It took quite a few hours designing, CAD'ing out and building this thing. I now know why the Pro-Cage shops charge $1400-$1700 for custom built cages, it take's lots-O-TIME! I thought about painting it red, but the rig is red.. so back to the stock cruiser roll bar gray.

Kusty: Yes the tight bends make for trick set ups in the bender. I am a proud owner of a JD2, Model 4 hydraulic bender and now the equivalent of a small country's GNP in die sets. A JD2 notcher also sits near the bender on a dedicated drill press (and now plasma modified..... hay part of the table got in the way of 45 degree notch's.. 40 seconds later the table no longer got in the way!) the tool does a great job. (tried the cheep notchers.....you get what you pay for!) I will post up a new thread with some shots of the bender doing the tight bends. I have a few cage's that I have to bend up over the next few weeks, I just need to grab the camera.

Rusty: Body only at this time. The rear is on full length mounts, calculating the front and rear mounts there is over 180 square inches of body sandwiched in 3/16 mounts and backing plates. However I will be tying the thing to the frame, I plan on using a bushing system I just need to source the materials. For now this is plenty, at the end of the month the rig goes into the garage for heavy maintenance, and loss of more sheet metal so I should be fine for now.

Mr. McGee: Ok well you did ask, (I don't want to violate the "no soliciting" rule, I like the rule and respect it, but I am not soliciting so here you go) I have started a short production run being sold in kit form.

Now to start on the tube fenders!

tube fenders are the BOMB

metalmender = the way to do it!!
(im copying his for my 45 buggy) :D

also dude, the centre hoop has a small piece of tube on the outside, if you wheel in trees a lot, you should extend that way out too the centre, (the part extending forward, wont look as good) but it will SLIDE past trees, overhanging rocks on big sidehills and so forth, i dig the head protection of driver and passenger, maybe those bars criss crossing the overhead section, should be attached to the main hoop, instead of the front hoop, for added head protection, sort of like reverse that around, obviously it was all done for some reason, and i cant see that all just looking at pics, not trying to criticise, more question and admiration!

but seriously it looks SUPER SWEET, i really dig it, does it fit under the hard top? (looks like it might) the back looks like it would allow for decent rear seating and rear protection, and the best part is your front dash area, and handles, they ROCK, i will certainly be copying that part

AWESOME
rob

Originally posted by helocat
Mr. McGee: Ok well you did ask, (I don't want to violate the "no soliciting" rule, I like the rule and respect it, but I am not soliciting so here you go) I have started a short production run being sold in kit form.

You're right--it is a good rule and i know you're not soliciting;)

a kit is even better! it would be nice to not pay for someone to weld it if i can do the same thing! I could possibly use two (two rigs)...just depends on price i guess:D When you get a price-lemme know!

thanks,
Max

super cool and tastefully creative. Right on!

Definately appreciate the "No Solicitation" on this board. When you come up with a price please contact me here or at:

Chris Kolloff
Atlanta GA
404.284.9890
ckolloff@hotamil

BJ: Thanks. Yes the over head bars can be in the reverse direction, however two things are lost. #1 the protection from things coming through the cage that may contact the driver or passenger. #2 Harder to get too the escape route if pined in the rig. One of the things I learned in researching these things is to keep in mind can you get through the cage if you are lying on your side? If the bars where the other direction, the driver would then have to climb over the steering wheal. May sound petty now, but lying on my side with my automatic transmission on fire (it is a 700R4 after all, well known for Car-B-Q’s) I want to exit ASAP!

The small side supports are there mainly for the reasons you stated! 90% of the wheeling where I am at is in the trees, by not going with the halo design I needed a way to keep the trees from hooking up with my cage. You are right if I moved them further forward in the front and raised the back, it would be a gentler push when I make contact. However I wanted them to also be supports for racking, so I kept them at 45 degree notches.

Yes a hard top would clear this just fine. The back area is intended for the fold and tumble forward facing seat I have yet to put in. (Zuk, Sidekick rear) Since the seat sit’s over the 34 gallon tank in the bed, an adult could make contact with the cross bar. If the tank was not there, there would be ample room for everyone. The rear seat will be holding my 21 month old (he thinks the FJ is his) and soon (next few weeks now!) baby #2.

The handles are one of those things that you don’t realize how nice they are entail have them! They also help you get in/out with control so you don’t KO yourself on the bar.

awesome! i got an on-board extuingisher on either side on main pillar for driver and opposite side for passenger..... being diesel and manual, i hope never to have a fire.....

i was only thinking of those side things, to brush past trees, cause mine keeps hanging up on trees, if you have seen my cage the sides make good tree and ledge catchers :p it looks great but needs a re-design!

the two main hoops jut a fair way out past the front hoop support, and i have been thinking about adding an additional "slide" bar, along with doing 4000 other mods to my truck ;) as we are all doing and running short of time! :D

Originally posted by helocat
BTW: Eric D. Nice avitar cruiser shot of Hog’s back! Now I thought you where a mini truck guy? Are you going up for the Flat Broke Poker run this month?

:eek: :eek: Man! good eye! I know what the picture is from and I look at it and cant even tell. You know your TSF!

Not a mini truck guy FJ through and through. My FJ is in the garage. I broke down and am going 1 ton, and some body mods. You want to loan the bender out in a month or two. :evil:

helocat great job heres to you:beer:

Originally posted by rockdawgfj40
helocat great job heres to you:beer:

i figured once you were a "wheeler" you would stop padding....:rolleyes:

Damn fine job on the cage. I may be wrong, but I think I found one of the features you copied off of another cage. Did you get the diagonals from the rear hoop down toward the center hoop from Nolen's cage design?
I just ordered some 2'' DOM to make my new cage, and I will probably steal an idea or two from ya so I dont end up with the exact same cage as I built for Nolen. :D

Rusty, Lots of people are using your ideas ;)


helocat,
Dam fine cage there!!!

Rusty,

Yup the back diagonal supports came from two cages I have seen, and Nolan’s is the only Cruiser one. The other was in a Baja race rig I saw being built in Santee CA, in a race fab shop. I am straining to remember the name of the shop, they were right next to the Machine shop I was the marketing mgr./product developer/etc. for. This race fab shop now does quite a bit of proto work for the Tenneco Automotive (Rancho), or at lest they did three years ago when I was still living in San Diego. (The industrial park we were in was amazing for Baja fab shops, Ivan Stewarts Toyota shop was two blocks away and Cheneawa (SP?) was four blocks away, AutoFab one block away, and a good two or three other small shops as well)

They also used the pillar design I am using over a compound bent hoop. Like I said this thing has a good number of cage ideas rolled into one. You are obviously an outstanding cage builder/designer with Sir Nolen putting that sucker to the test! (Over and over and over and……) I look forward to seeing what you create for your rig! Help yourself to anything off my cage, that’s why I posted up photos to share my cage concepts.

Thanks Helocat. One of the many sad facts of living in La. is that there are very few shops that do any cage work or wild offroad mods unless you count dirt track racing. I would be highly amazed if those guys even know that there is round metal out there that isnt called pipe. Most of the cage ideas and other mods I do tend to come from pics here,or in offroad mags. I would be like a kid in a candy store if I was around fab shops like you describe.