I had a thread about the original build a few years ago. It has served me well over the years but it was time to make a few changes. This past summer my wife told me she missed the open air feel of our old CJ and that the doors off and the back chopped was not enough. She said it still felt too cramped inside. We weighed our options and starting over with a new rig was out of the question $$$ wise. So the next option was to cut the rest of the top and build a new cage for it. The existing cage was ok with a full top but as the main structure it was not going to cut it.

So I started going over designs I liked and didn't much care for. While I fabbed the jeep myself before I do not have the tools nor the skills to build a cage myself. I have enlisted the help of a local shop and builder named Dr.Smash designs in Carson City to work with me. The owner Eric knew how much I wanted to be invovled in the build so he has been kind enough to allow me to come to the shop and we work together on it. While finalizing the cage design with Eric, I decided it would be a good time to boatside it as well. Seeing as the rockers were totalled and we could build the A,B and C pillars off it.

This is what I started with. When I brought the jeep to the shop I had already cut the top and removed the windshield. The first order of business was to remove the rockers and start rebuilding them.

We mocked up the new rockers, straightened out the floor sheetmetal and got them burned in. We also tied in the rear fenders and the the front cowl area to the new rockers too.

I haven't decided on what I'm going to plate them with yet but that will come later. I'm also going to redo the floor sheetmetal and tie it into the rockers and seal it to keep water out.

We just started on the cage. Its mostly all 1.75" DOM but there will be some HREW spreaders mixed in. We got the B pillar and the rear portion tacked in last week. All the measurements for the A pillar were taken last week and we'll get them bent up tomorrow hopefully. I can only make it out there on Friday's due to my work schedule. Working graveyard sucks.

I was hoping to have new suspension seats for the front and back to work into the build but $$ needs to go elsewhere and this is afterall just a toy. I have 5" between my head the cage when seated in the driver seat. The seat is in the position I drive in.

Anyway here is the start of it. I will get more pics as we make more progress.

I'll get some pics of the old windshield pillars and the rear door area where they were cut. Eric massaged them so there are no big holes left from the cuts. We were going to just cap them but Eric was able to make some more room for the C pillar by doing it the way he did.

Eric got some more done today and will have more by the end of the day. The A pillars are in, windshield spreader and dash spreader and the harness bar is in. There will be an X behind the front seats and rear bench. So here are a few new pics.

ill be watching this..still dont know what i want to do with my rolled xj..cutting the roof was an idea..what are you going to do for a top? just a canvas top or what?

ill be watching this..still dont know what i want to do with my rolled xj..cutting the roof was an idea..what are you going to do for a top? just a canvas top or what?

No top for now. I may do a snap on top for summer to keep some of the sun off my daughter. It would be a mesh type or maybe canvas I'm not sure yet. I'll have more pics tonight

This is how she looks right now. I love the looks, we plan on finishing up the fab tomorrow.

do you have any pics of where you tied in the tube at the top of the cage?

do you have any pics of where you tied in the tube at the top of the cage?

Not now but I'll get some tomorrow

Nice lines in the cage. Looks good can still take the family out.

Nice lines in the cage. Looks good can still take the family out.

Thanks, I'll get more pics up later today after we get done working on it.

I like it.

Looking sharp. I've considered the idea myself, but it gets so damn cold here in the winter...

Btichn Man!

Have you thrown a seat in it yet? I like the angry eyebrow, but it almost looks a little too angry. Like its too low.

Totally diggin the work tho. I always wondered what a rig would look like cut the way you did...and I like.

when i first saw the whole top cut off i was like holy shit that looks awful. but you really made it look good with the cage, nice work so far.

here is where I left it today at beer thirty

Thanks for all your hard work Eric. Anyone looking to have quality, top of the work done should give Dr. Smash a call!!!!!


Here are a few other pics of it. Most of the gussets are in and the sick X off the B pillar. The compound bends in this are unreal. Eric did a great job with this one. He did an amazing job of putting what was in my head into motion and then tweaking it some to make it a Dr. Smash original.

There is still work to be done but its definately almost there.

nice build

very nice build. just might have to go cut the top off mine now.

Thanks for all the positive feedback. I can only take credit for the idea and Eric ran with it.

She's almost all welded up and almost ready to be picked up. The rear foot plates and the B-pillar x-joint are not finished welded in these pics but they will be. Here are the finished cage pics. There are a ton of cool details and extras that the pics don't do justice to.

a final few.....It came out fawking awesome, that's all I can say

badass cage bro. Nice idea

Holy hot damn, I really like that cage work! The door bars really set it apart, looks great!

Holy hot damn, I really like that cage work! The door bars really set it apart, looks great!

Thanks, I think they look awesome too and they make a very comfortable, natural feeling arm rest.

Awesome! Man I love this jeep.

Can we get some pics of how it's tied into the frame?

Awesome! Man I love this jeep.

Can we get some pics of how it's tied into the frame?

The A, B, and C pillars are built off the new boatsides and the D pillar is tied to a footplate that is welded and bolted to the floor directly above the rear shackle hangers.

The boatsides are built off the reinforced unibody. I plated the unibody with 3x3x.250 angle which is stitch and rosette welded and for added security I added 3 - 3/4" bolts per side through the unibody. I still need to plate the rest of the front of the unibody. The driver side is almost all done but the passenger side still needs work and has a small buckle just behind the bumper mount fromcoming down really hard on the front bumper last summer.

I really dig the little gussets everywhere and how you did the roof. The roof especially.

I really dig the little gussets everywhere and how you did the roof. The roof especially.

Thanks, I told Eric I wanted a huge intersection with the top tubes and it came out just how we talked about it. Eric even added some speed holes to those little gussets:D They came out great.

I need to go by the shop this week and finish up the sheet metal work to tie the floor back into the boatsides.

Thanks, I think they look awesome too and they make a very comfortable, natural feeling arm rest.


I like the ''arm rests'' as well, how do you get in though? Bo and Luke style?

I like the ''arm rests'' as well, how do you get in though? Bo and Luke style?

Yep gotta step into it, its going to take some getting used to but it will be safe and strong.

That's a badass looking cage. Great job so far.

Looks Great, Well thought out design.

Looks Great, Well thought out design.
Thanks, Eric took my idea and ran with it. I'm going to finish up the floors this week and I'll snap a few more pics then. I'm going to work new sheetmetal from the existing floor to the new boatsides

done yet? i need somethin pretty to look at..

done yet? i need somethin pretty to look at..

Sorry not yet. I work graves right now and can only get out there on my days off. I'll be out there Thursday and Friday to finish it up and bring her home. Time for new paint. I'm thinking a bright metallic blue body w/ a granite color for the cage. I don't want it to be black and hide all the kick ass detail in the tube work.

And I'm looking for some 1/2" UMHW to plate the boatsides with but God damn is a sheet expensive. Anyone have any extra or scrap they want to sell or get rid of?

hands down one of the sickest XJ cages Ive seen!

Great job on the cage, easy to see lotsa time into it. No offense intended but why not just build a buggy???:confused:

hands down one of the sickest XJ cages Ive seen!

Thank you, I will pass that in to Eric

Great job on the cage, easy to see lotsa time into it. No offense intended but why not just build a buggy???:confused:

I definately thought about it but I couldn't afford to start over plus I'm happy with my jeep and the way it works. I really just didn't want to start over and I like that it's still my ol' XJ at heart.

And I'm looking for some 1/2" UMHW to plate the boatsides with but God damn is a sheet expensive. Anyone have any extra or scrap they want to sell or get rid of?

Take a look at THIS (http://www.interstateplastics.com/Black-Uhmw-repro-Sheet-UHMBR.php?sku=UHMBR&vid=200910231754-7p&thickness=0.500&dim2=16&dim3=36&qty=1&2=Price+it+%3E%A0%A0) place, they cut to your dimensions so you only pay for what your getting. oh yeah and its black.

slick!

Looks sweet and safe. Hate to play devils advocate but what are the planes to counter all that new weight and considering in it's location. Alot safer and looks awesome but what performance downsides do you see and how do you plane to counter them? Not trying to be a dick just wondering.

Looks sweet and safe. Hate to play devils advocate but what are the planes to counter all that new weight and considering in it's location. Alot safer and looks awesome but what performance downsides do you see and how do you plane to counter them? Not trying to be a dick just wondering.

As far as plans go, I'm going to wheel the shit out of it. Previously the rear doors were on it all the time. They were full power doors and windows and heavy as hell. The old cage was really heavy, as well as all the jeep I cut away. The top is gone,windshield, A and B pillars and the rockers. Yes I the new cage and is more elaborate and definately will add weight but the difference between what it used to weigh and what it weighs now is probably not much if anything.

So there should be no performance issues. Is strictly a crawler not high speed. It gets trailered to each run. The Con is about 1.5 hours away as is Fordyce and Moonrocks. Those are the trails I run. It sees roadtime but only around town. It has 5.38 gears so its not much for the highway.

Thanks for asking though.

Had to ask. I run mud often as it is everywhere out here and wanted to here the from someone who has an intense cage how they thought it weighed out. Still think I will hold off till I get a tow rig and get sick of rooster tails. Also a long hall for me to find rocks. Thanks for the response.

Awesome. Im doing the same with mine. I needed ideas

So there should be no performance issues. Is strictly a crawler not high speed. It gets trailered to each run. The Con is about 1.5 hours away as is Fordyce and Moonrocks. Those are the trails I run. It sees roadtime but only around town. It has 5.38 gears so its not much for the highway.

Thanks for asking though.

You still planning on rolling around town with it?? Man wish PA was like NV..:shaking:

how about a update on this :smokin:

I have to admit I was worried when I first started reading, cuz I've seen a lottttta ugly cages... but this thing is fucking PERFECT! You guys nailed the lines, shape, everything. Definitely one of the nicest cages I've seen, if not the nicest. Almost makes me want to chop the top off my girlfriend's near-mint XJ... hmmmm :smokin:

how about a update on this :smokin:

x2!!!

Some very nice tube work there. Love the lines.

You still planning on rolling around town with it?? Man wish PA was like NV..:shaking:

Yep, I'll still drive it around town. Since I'm a cop I know the traffic laws well.

As far as Nevada goes, what do you expect we allow gambling and prostitution.

I have to admit I was worried when I first started reading, cuz I've seen a lottttta ugly cages... but this thing is fucking PERFECT! You guys nailed the lines, shape, everything. Definitely one of the nicest cages I've seen, if not the nicest. Almost makes me want to chop the top off my girlfriend's near-mint XJ... hmmmm :smokin:

Thanks!

Now get in the garage and get to cuttin'.

x2!!!

Some very nice tube work there. Love the lines.


Thank you. As far as updates go...I have the cage painted and the primer on the body. The cage is a granite color (grey) and I'm debating on the body color. My wife like yellow, I like orange and my daugther likes a metallic blue cause it has sparkles in it she says.

I have sheet metal cut to fill in the holes in the cargo area and I'm still looking for plastic sheet to plate the boatsides with.

Then its on to wiring. I have to figure out what to do with the wire loom that runs down each side. They're ugly and in the way. Then its on to find a way to mount the fuse box that was on the inside of the passenger kick panel.

I was able to get the rear bench seat mounts figured out. It was easy. I'll get some new pics up soon.

great job on the tube work. what type of bender are you using? You should make a sandrail next since sand mountain is not too far away! :D

Thank you. As far as updates go...I have the cage painted and the primer on the body. The cage is a granite color (grey) and I'm debating on the body color. My wife like yellow, I like orange and my daugther likes a metallic blue cause it has sparkles in it she says.

I have sheet metal cut to fill in the holes in the cargo area and I'm still looking for plastic sheet to plate the boatsides with.

Then its on to wiring. I have to figure out what to do with the wire loom that runs down each side. They're ugly and in the way. Then its on to find a way to mount the fuse box that was on the inside of the passenger kick panel.

I was able to get the rear bench seat mounts figured out. It was easy. I'll get some new pics up soon.

My vote is for Blue or Orange ;)

As far as UHMW goes, I just picked up some more for my flat-belly from the same place I used for my boatsides. They've got the black reprocessed material too which is nice :smokin:

Interstate Plastics
330 Commerce Circle
Sacramento,Ca. 95815

They've got a place up in Idaho too, as that's where my sheet shipped from. I usually just email Bruce Luber. bruce@interstateplastics.com, 866-899-5139

Just for a cost idea, I paid $75 for a sheet of .5"x26"x37" shipped. For my boatsides I paid $109 for 2 sheets of .375"x14"x60" shipped.

Haha I was about to post about that company in reference to you, I'm not sure I knew it was that cheap! Damn I need to buy the sheets...

They've got a place up in Idaho too, as that's where my sheet shipped from. I usually just email Bruce Luber. bruce@interstateplastics.com, 866-899-5139

lmao his name is Luber and that UHMW stuff is supposedly naturally lubricated :homer:

awesome build! I love the aggressive look.

Bad ass cage that is fuckin sick! I love the lines of it and the quality work it looks amazing! Want to see some updates!

I got the material for the boatsides. It was free so I couldn't pass it up. Its only 3/8's (I wanted 1/2") but the price was right. It came from a friends coworker. Its used on top of snowboard boxes at Kirkwood, its slick as hell. It should work, there is not alot of room between the spreaders so it should have lots of support. I was given 2 full sheets (5'x8') so I have extra if there are issues with it.

The cage is painted. The body is primered and waiting for new paint.

I got the plastic cut just need to mount it up. I fabbed up the new rear seat mount since the old ones were cut out with the old rockers.

I'll get some new pics up soon.

It's on the road again. Here is a teaser pic of the new color. Its gloss real orange and the cage and accents are satin granite. They look good together.

It still needs quite a few things to be trail ready but it drives down the road just fine. Its been overheating when crawling and needs a water pump bad. I need to line the tub and move some wires.

I got pissed drilling and tapping the boatside supports to mount the plastic so I stopped that. There has got to be a better way to mount the plastic then drilling and tapping into the support legs. I may just use sheet metal and weld it.

Anyway here's a quick driveway shot. I'll get more pics later.

We just started on the cage. Its mostly all 1.75" DOM but there will be some HREW spreaders mixed in. We got the B pillar and the rear portion tacked in last week. All the measurements for the A pillar were taken last week and we'll get them bent up tomorrow hopefully. I can only make it out there on Friday's due to my work schedule. Working graveyard sucks.

I was hoping to have new suspension seats for the front and back to work into the build but $$ needs to go elsewhere and this is afterall just a toy. I have 5" between my head the cage when seated in the driver seat. The seat is in the position I drive in.

Anyway here is the start of it. I will get more pics as we make more progress.

I'll get some pics of the old windshield pillars and the rear door area where they were cut. Eric massaged them so there are no big holes left from the cuts. We were going to just cap them but Eric was able to make some more room for the C pillar by doing it the way he did.

Looks great man! What wall is the 1.75 Dom? And is it up racing rules?

HELL YEAH!! looks great, the cage is by far one of the best looking XJ cages I've seen! Lets get some more pictures of this thing! :beer:

Looks good man! :smokin:

How hard is it to get into with the "door/seat" bars a part of the cage?

Looks great man! What wall is the 1.75 Dom? And is it up racing rules?

It's .120 and I have no idea about the racing rules. I don't race it, just for the Con and family wheeling. I've done one "comp" if you call it that. It was RenoRocks at the Sands. It was fun, all man made gunnite courses. I placed 3rd in the Unlimited division club challenge.

Looks good man! :smokin:

How hard is it to get into with the "door/seat" bars a part of the cage?


Its easy, just Dukes of Hazzard style. The rears might be harder, I haven't tired to get into the back but as long as my daughter can (and she has) that is all I'm really worried about.

Cool! :smokin:

Looks nice and safe for the girl too! My girl was in my XJ the last time we rolled it. She has been hesitant in getting back in. LOL! Roll cage did it's job though.

Again, looks good man! :grinpimp:

That is a great looking rig. I might steal some of your ideas when I decide to take the top off.

That is a great looking rig. I might steal some of your ideas when I decide to take the top off.

Thank you, I'll get some more pics up of everything all painted up soon. But there is still more work to do and no money to do it with.

Here's a pic from a buddy of mine. My local 4x4 club was in a parade. This was taken in line waiting to go. You can get the side profile perspective here.

My daughter and some of her friends were in the back.

looking awesome man I think thats the best looking chopped XJ I have ever seen!

I read about your jeep in jp mag. And thought it was awesome then, but man its badass now. If im ever in nv and get pulled over I hope its you lol

Jungle Gym for the kids, gotta love it! :lmao:

I read about your jeep in jp mag. And thought it was awesome then, but man its badass now. If im ever in nv and get pulled over I hope its you lol

Thanks bud, that means alot. That mag article was awesome and getting the cover was unreal.

Come to Lake Tahoe and have some fun gambling at Stateline and look me up, that's part of where I patrol.

Finished product looks great! Should come that way from the factory :laughing:

Baby on the way?

Baby on the way?

Well my wife just found out I was selling it and got pissed, so its not for sale anymore. She told me just to fix it. So I'm going to do that.


Oh and no baby on the way, in fact I got snipped Wednesday afternoon so that is no longer a possibility:D

Glad to hear would have hated seeing this thing go to some spoiled rich kid or something keep up the good work it looks awesome so far

Also glad to hear yours is the one that finalized my decision to go tons. Keep it up

Well hope u dont mind but going to try ur cage on my rig with a twist..... Its a dovetailed jeep

Well hope u dont mind but going to try ur cage on my rig with a twist..... Its a dovetailed jeep

No worries brother. Go for it.

I'm getting ready to cut the rear quarter panels off and tube the back. I plan on keeping the stock floor pan in the back as the cage is built into it. I'm going to have some fullsize xj gear taillight cans for sale soon.......Need to pay for more tube. :D

I finally finished plating the boatsides. I was going to use plastic and drill and tap the new rocker supports but that proved to be a major PITA! So I had a buddy cut some 1/4" plate for me on his laserjet and I burned them on. I'll get some pics up tomorrow in the daylight.

Still having overheating issues too. Replaced the fan clutch and water pump. Tried to flush the radiator as best as possible. I think it still has air in it. The temp gauge will peg to 260* but its not boiling over and the overflow is not full. Very strange. Also I found the aux fan is not working anymore so that can't help. Time for a new one. I think a grill deep water crossing at Fordyce may have been the cause of that issue.

I had some heating issues flushed my system completely out dropped to a 180 thermostat and put some water in. With my twin electric fans doesn't get above 180. The electrics are 34 a piece at checker 900cfm one is wired to the old back up fans wiring for thermo activation other is on a switch..simple 1/8" flat stock mount.. just my .02 worth helped mine out a lot

word on the streetz is................... yous is gettin a 60. nice talking with you today geoff, i cant wait to come down and get that 44

word on the streetz is................... yous is gettin a 60. nice talking with you today geoff, i cant wait to come down and get that 44


I have no idea what you are talking about........:smokin:


But with the 60 I can finally throw on some 42" Rockers!!!! Shoot me a PM or call when you want to come down Dave.

Here are the plated boatsides.....1/4" I left the ends open so I could still use my high lift if necessary.