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Old 01-26-2014, 11:43 PM
Brucker Brucker is offline
Trail Ready
Join Date: Jul 2013
Location: Longmont, CO
Posts: 418

Time for some cage work. This time around, the client wanted a simple 4 point interior cage. By 4 point, we are referring to the amount of points the cage will be tied into the frame. It will be constructed out of DOM round tubing and tied into the frame using bushings. We will also be tying in the factory roll bar to the new tube work, stiffening the entire chassis. Eventually the plan is to eliminate the factory portions with new DOM throughout and adding 2 to 4 more frame tie in points.
Start off by making a few different sets of cage feet. Two sets for the A pillar and two sets for the B pillar; an interior set at each pillar as well as an exterior set. The difference between the interior plates and the exterior ones are the length and width dimensions. Having one side lager than the other will help keep the cage from easily shearing through the body during impact.
Below we show a top set of cage feet.

Then position the plates, layout for the through holes, and drill the 4 holes at each location.

Taking into account the very limited interior space, and the fact that the client wants to be able to still be able to fully use his seats (including being able to still flip the back seat down, completely flat), we bend up the first bars. The floor bars will be just that. They will connect the A pillar to the B pillar on each side along the floor. The rest of the cage will then be built off these tubes. After bending up the bars we begin to fit them into place:

Once both sides are fitted properly, we pull the seats again, and weld the bars to the plates as much as space allows.

Last edited by Brucker; 03-14-2016 at 11:55 PM.
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