We need to have a cage building party. I figure a few weekends and we can knock out a bunch of cages for us as most of them will be pretty close to the same thing.

I can offer up my welder (220v) and my plasma (110 or 220) as well as my air compressor (110). I can also pick up any tube needed with my trailer. I just dont have a spot to do it.

I am in for 60ft 1.5" tubing. .120 or .134 thickness.

I'd be up for it and would even offer to have it at my place although it is starting to get toasty out here already and getting warmer. Another issue is I don't have a whole lot of room to swing long lengths of tube where I have my bender set up. If someone was willing to have the bender set up at their place as well as having to drill 2 holes in the concrete to mount the bender, I wouldn't mind bringing it over.
I was at Kartek today and they must have had about 10 or so JMR hydro tube benders on the showroom floor. Wish I was in the market for one cause I would've bought one of those for sure.

Why do you people live in the west coast ? :(

I agree, seems like the guys on the west coast hook up more then us on the east coast.

But that is a cool idea about getting several cages knocked out.

Man, I'd be down for that! Too bad I won't be in the area until late June.

so iz and josh lets have our own.. just lend me the money for tube :)

Man, I'd be down for that! Too bad I won't be in the area until late June.

We can do something if you want in June, if your back in time for a Rubicon run..

I'm in (with or without my truck)

I've got my bender w/ trailer hitch mount, 1.25, 1.5, 1.75 dies and a tube notcher. :thumbsup:

And No, Stic-o, the Focus is not getting a cage. :p:

Why do you people live in the west coast ? :(
'cause we're cool. :cool: :D

How much tube do you think the explorers will take? The Rangers would go quick, but the Explorer will take a little more time. I'm already got the OK to get me a winch, but I think I'd rather have a cage if I can do it for about the same. can't have both though:( Try to get a place this year, so really try'n to focus on that and keep the money going into the truck this year. Jefe and Matt I'm sure you can both relate:(

I'll talk to my dad, and see about maybe using his place, not sure though.:rolleyes: Also the place I got tube from last time was pretty cheap. and they will do free delivery, next day:D Here's the place if any body want to check prices.;)

http://www.tottentubes.com

How much for you think for a Ranger?

I may be interested.

I was figuring 100' for my rig with no mistakes, caging all the way to the D pillar. My plan was for the B-pillar hoop out of 1.75 and the rest 1.5, all .120 wall.

I really want to chop mine before I cage it. I'll be there either way whenever we decide to do it.

I was figuring 100' for my rig with no mistakes, caging all the way to the D pillar. My plan was for the B-pillar hoop out of 1.75 and the rest 1.5, all .120 wall.

Just went down and measured the truck. That's about what I came up with:D

Are we talking DOM or mild steel here?

I think this is a pretty sweet idea, i'm definately in...we can possibly do it at my place as well if it doesn't work out at anyone else's place...and as far as using DOM vs mild steel i personally will definately be using DOM

Here is how I can see it working out. Just a few ideas.

Froader and I will use the same A piller as we have the same dash.
Jefe, stic-o, and DB1 will use the same A pillar

My B pillar and DB1's C pillar will be the same

Jefe and stic-o could pretty much bend up the same exact cage. The b pillar back might even fit Froader's as well by just leaving out the D pillar if he chops the top.

DB1 might be able to use the same B pillar as Jefe and stic-o

I am figuring a standard cab ranger will take between 40 and 60 feet. An extra cab might even get by with 60 ft as well depending on how crazy you get.

If we all gut the interiors before we get together that will save a bunch of time as well. Another thing we could maybe do is depending on how many people we get in on this everyone tosses in $20 and we do an air over hydro conversion on one of the benders. It will sure save a bunch of time. It might be worth buying a copy of bend-tech so we dont waste a bunch of tube.

Just my 2 cents.

Wow, I can't believe I'm saying this:confused: I'M GLAD I ROLLED!!!!!!:D :D :D If this is what it takes to get my friends to cage up,..it's a small price. TDS was my best trip ever:navajo: I'm a haapy man. Count me in to the paaartyyy:hammer:

Here you go 4 doors.

Here's some ideas.

More.

Matt, what was you'r thoughts on floor plates? Pre-made or making our own? Also our we welding or bolting through the floor? I know IMS had premade floor plates I think, but can't remember how much there are. BTF has some too, but at $8 bucks each! :eek:

I already have a bunch of the pre-punched plates from IMS. They're about 4"x4" with four bolt holes punched in the corners. I imagine I grabbed 16 to bolt an 8 point cage in through the floor.

I already have a bunch of the pre-punched plates from IMS. They're about 4"x4" with four bolt holes punched in the corners. I imagine I grabbed 16 to bolt an 8 point cage in through the floor.

Yeah That's the ones I was thinking of. ;)

i wanna cage

Yeah That's the ones I was thinking of. ;)
I grabbed them just before steel prices shot up. Unfortunately I didn't grab all the tube then. :(

Anyone have an idea of what a 20' stick goes for these days?

Matt, what was you'r thoughts on floor plates? Pre-made or making our own? Also our we welding or bolting through the floor? I know IMS had premade floor plates I think, but can't remember how much there are. BTF has some too, but at $8 bucks each! :eek:

I was thinking the pre made plates from like IMS. I was thinking that we should concentrate mostly on doing the interior parts when we get together. Frame tie ins can be done at another time and are easier to do individually. Trying to bend a 20ft tube by your self sucks. Especally when you get into doing complex bends. I plan on bolting mine in then come back later and do the frame tie ins.

How complex is everyone thinking of getting? I wasnt plannig on getting as crazy as the one that chris posted pics of. I am thinking something like what fakrwee has. If people are wanting seat tie ins and everything else we would be spending a full weekend on just one person. I am thinking just doing the pillers and a few braces from hoop to hoop. Maybe a diagnal behind the seats and thats about it. Anything more complex then that needs to be done by a shop or individually later on.

My idea was that because we all have rangers and explorers building the first one will take the most time. Once we have that one nailed down the next few will go fast as we will have the measurments and dimensions figured out. As long as everyone agrees on wanting the same design then it will go fast. If everyone wants a custom cage built differently then it wont work.

I am willing to bring my tools and help. Another thing is that I think each person should be responsable to weld their own cage up. I am not a pro welder and dont want the risk of welding other peoples cages. Each person has to be incharge of there design make the final call on what they do.

Anyone have an idea of what a 20' stick goes for these days?

About a month ago I got a 20ft stick of 1.75 .120 HREW for under $40 out the door. I didnt price anything else.

My idea was just 4 hoops at the A-D pilers tied together along the roof line, then a cross bracing in about the middle on A-C. Pretty simple. You can always add to it...just ask Rick! :p:

Another thing is that I think each person should be responsable to weld their own cage up.

I'm gonna Die! :(

Simple works. Here's a couple of shots of mine being installed.

FYI

There is 104' of 1.75 .120 DOM tubing for sale on dezertrangers...

$365, don't know if it a good deal or not, but if it is;go get it!:D

http://dezertrangers.com/cgi-bin/ib/ikonboard.cgi?;act=ST;f=16;t=51957

I have a basic idea of what I want but I'm still debating on how I want to do the dash area. If I could just get the 2 big hoops done then I can take it from there. I'm thinking B and C pillar hoops and then coming off the B pillar hoop into or around the dash somehow. I need to start measuring for the tube I'll need.

I'm gonna Die! :(

ahahahahaha that's good!

I know i have a different application with no cab :D but if i could help with any pictures i will.

I am thinking something like tom has. Do you have any more pictures of the a pillar?

I know i have a different application with no cab :D but if i could help with any pictures i will.

Your just a step ahead of me. Once the cab is ruined then it will get cut off. Then my inerior cage will become my roof.

Found these universal mounting plates on the A&A mfg. site...4"x3"-3/16" thick with (4) 3/8" holes $2.45 ea.
http://www.aa-mfg.com/pdshop/shop/item.asp?itemid=995

I may end up making my own depending where the legs land. I know the space is pretty narrow where the C-pillar legs go on my truck.

I don't need or want a jungle gym. Just a simple cage here. Much like Toms, but for 4 door.
B-pillar hoop, C-pillar hoop, pass and driver side A pillars, cross bar at top of windshield (and bottom if it can be out of the way?), angles from C-pillar to rear, roof ties between B and C hoops, and a couple of diagonals (1 behind front seats, 1 behind rear seats going opposite direction, 1 across roof) I'd draw it up, but I can't free-hand worth crap, and the only other way I know how is a full 3D CAD model. :p:

Gut interior except drivers seat and dash before hand, and all the hoops and pillars should go very quickly once one is done, all the straight tube even faster. I agree with the welding part too, perhaps we just tack everything together and let everyone weld another time on their own, or let them hire someone.

Now where are we going to do this? I'm positive that if we did it at John's his neighbor would go postal :eek:, so thats out. Sorry.

I'm gonna Die! :(
ROFL

Oh wait. . .thats not funny, 'cause its probably true. :o :p:

Are you and your dad still stuck on stick? I'm sure you could get some decent welds with a MIG and a little practice. However, welding tube is still difficult even in uncrowded conditions.

Found these universal mounting plates on the A&A mfg. site...4"x3"-3/16" thick with (4) 3/8" holes $2.45 ea.
http://www.aa-mfg.com/pdshop/shop/item.asp?itemid=995
Thats almost exactly what the IMS plates are, except square, and cheaper i believe. As for weld-in or bolt in, and whether to tie into the frame. . . I was opposed to the weld-in w/o frame tie-in on Toms, but i didn't see any deflection of the body and that was a couple of HARD hits and the cage obviously saved the A-pillar from crushing in. My original design was for bolt-through with no frame tie in. but I'm thinking I'll just weld the base plate in like Toms. :thumbsup:

My thought was to bolt through the body and the frame tie in coming up to bolt to it. Weld to frame. The only reason I' would go with something with rounder corner for the floor plate vs. the sqaure ones, is I have heard of "can opener sydrome" in a roll the corners rip into the sheet metal like a can opener.

We still have a MIG, I have used it a few times, and actually I feel it's easier with it. I just haven't done much welding yet.:rolleyes:

Jefe, we're you going to remove the headliner too? I'm guessing yes.

The other thing that worries me is the drivers A piller. I don't want the tube to get in the way of the headlight swich, or preventing me getting to the insterment cluster. My thought was to run down the side of the dash, but then the fuse boxs is in the way. Thoughts?:dunno:


Maybe we can do a live web feed too like Colin's engine swap:D

toms cage tied into the floor only with no drops to the frame???????????????? just calrifying.
My cage will be built for a light roll, not for nascar but for the type of wheeling we do.....

I was pretty much planning on going through the floor directly to teh cage and also plating the BII cab to the frame and running solid mounts, but maybe this is overkill for my trucks use?

Here's my 2cents on it..

http://www.explorerforum.com/forums/showthread.php?t=136119

I've been searching my pics and here's a couple of more. We decided to weld it done versus bolting and reenforcing cause we figured in rock crawling rolls are slower and less violent.Exactly what happen to me. Brian has some close up fotos of the damage to the top. Hope's he post them, he's working this week.

First one is the spare mount tied into the cage.

Man I really want a cage bad. I like the one with the top cut all the way down the center and then caged all the way.

Couple of more.

Tom how long did it take you to build that cage. I really want one and this is my dd. Just wondering on the down time. Might have to push this up on the list now.

Tom how long did it take you to build that cage. I really want one and this is my dd. Just wondering on the down time. Might have to push this up on the list now.

Which tom?

DWD's took 2.5 days; basically a 3 day weekend. 12hrs of dry time for the paint..

Tom how long did it take you to build that cage. I really want one and this is my dd. Just wondering on the down time. Might have to push this up on the list now.

It was done at 4Xdoctor in Burbank, Ca. I had no idea on how to do it and took it to a pro. With everyhing stripped out it took them 1 day and a half. and that was because we switched design half way thru. I decide to take the rear seats out and put my spare tire inside attached to the cage. It worked, we rolled but the spare tire and spare axles never budged.

Which tom?

DWD's took 2.5 days; basically a 3 day weekend. 12hrs of dry time for the paint..

You work. LOL Thanks.

Edit: Thanks also Fakrwee. didnt see your post till after i made this post.

Jefe, we're you going to remove the headliner too? I'm guessing yes.

The other thing that worries me is the drivers A piller. I don't want the tube to get in the way of the headlight swich, or preventing me getting to the insterment cluster. My thought was to run down the side of the dash, but then the fuse boxs is in the way. Thoughts?:dunno:

Maybe we can do a live web feed too like Colin's engine swap:D
I'd keep the headliner and trim. I was planing to run the A-piller outside the dash, cutting into the plastic door panel. Yes, the fuse box would have to be relocated (just unbolt and turn it around so its gotten to from under the dash, in theory anyway). And the webcam would be a must. :cool:

toms cage tied into the floor only with no drops to the frame?
That is correct. The pics he's posting of the tie-in to the body is all there is. No plate underneath. After personally testing his cage in action :D I have no problem doing the same. I have never wanted to tie my cage to the frame as it complicates matters (frame flex, seat mounts, solid body mounts or bushings through floor, complicated bends and/or horrible cage locations, etc)

Now where are we going to do this? I'm positive that if we did it at John's his neighbor would go postal :eek:, so thats out. Sorry.


I started thinking about that as soon as you guys mentioned a cage party. I wonder if I could get them a family pass to Disneyland for the day? or two?
(or find out when they might be gone on vacation - more parking spots)

I talked to my Dad. We're a go! :thumbsup: :D

Plenty of room there to bend the tube. Just need to figure out when, and maybe we could set up the bender ahead of time, so we don't have to worry about that the day we start. We should figure out how much tube we'll need all together and get it all at once. Maybe we could get a better deal then too. We can do some BBQ, and make a group thing out of it. Anyone who wants to come and help. O' and a web cab cam of it.:D

What do all think?

I'd also be willing to take a friday off to get started early on it.

I won't be building a cage for mine due to finances, but I'm down to help out.

I won't be building a cage for mine due to finances, but I'm down to help out.

That's because you bought a bumper:D

Colin...Shold I paint my cage...RED?:p:

Yes, with black pads. That would actually be a good accent.

That's because you bought a bumper:D

Colin...Shold I paint my cage...RED?:p:

Make that glow paint.

Rios has pretty much exactly what I was thinking. Just leave out the bars going back and thats what I am thinking.

What is everyone think about adding an air over hydro ram to one of the benders. There are some write ups on Pirates about it. I have a stand we can build off of. Just need to buy the ram. It will speed things up a ton if we do it.

I also have a roto hammer if we need to drill concrete for the drop in anchors if we do it manually.

I don't know much about the air over hydro set-up but i'm all for it:thumbsup:
I've also seen a few write-ups where people were using a ram from Harbor Freight. In any case, figure out what we need, how much parts will be so we can break down the cost for everyone who can pitch in.

94562-0BDA is the ram from HF. $80 plus tax. I have a stand we can modify to mount it on. We will need some all thread and nuts to make leg levelers and some scrap steel Im sure we all have a little of laying around and we should be good. I see $120 or so in materials needed.

The people I have as in are:

RockRanger
Stic-o
Jefe
DB1

Maybes

Froader
RJ

When do we want to do it?

I am pretty booked between now and early april. Maybe get together mid to end of april and build the bender up and take some measurements. Then do a build day or two in may? Is anyone planning on going to moab that this will interfear with?

No Moab for me, but I'll bet Jeff and John will go.

We have our Big Bear run in april, but willing to work on trucks instead if need be. Other then that I'm pretty open.

. . .but I'll bet Jeff and John will go.
Yes we are.

And my truck being in on this is all theoretical as people are starting to bite in my for sale thread. :thumbsup:
I'm still in either way though. :cool:

Nobody is thinking exo??? Besides the looks why not exo?? Seems like it would be easier (yes Jefe I know its to late for you) and I really like my body panels dent free. I'm interested but I'm not very close.

We have our Big Bear run in april, but willing to work on trucks instead if need be.
I'd just as soon hang at the cage party as wheel. :thumbsup: :D

Maybe a tiki demo at the party...? :D

exo cages are over rated, they take more steel and are not nearly as strong as an internal cage without adding all kinds of support, plus rocks dont like to hit tubes they like to go around them and hit the metal behind the tubes...

just my 02

I wish I was in CA I would be joining this party

Rangerx's Exo cage doesnt count, its too well done and easy on a Ranger :)

I'd just as soon hang at the cage party as wheel. :thumbsup: :D
Especially if we're going to be freezing in Big Bear.

I can work with any dates, i'll let you guys decide then i'll keep that date open.

Rios called me today and told me about this. Room for one more Explorer??? I can just tow it up there with the interior out and camp out in the RV in Steve's parents front yard for a few days. I think I need a cage.....in light of recent events.:roll: :roll: :roll: :roll:

Oh, I think it would go faster if persons who are real good at doing a certain step, like bending tube, do that for everyone, or at least be in charge of that step. Along those lines, I would imagine a few of us are much better at welding than the rest. I don't mind welding, but it would go a lot faster if someone took over that part who was actually good at welding. I realize one would get pretty good at it after welding up an entire cage, but that could take some time.

Tom Rios, could you pull the carpet up and look at how well the cage held up where it mounts to the body? I know the exposed parts did great!

Tom Rios, could you pull the carpet up and look at how well the cage held up where it mounts to the body? I know the exposed parts did great!

Sure, I'll get some tomorrow. I'm pretty sure nothing moved. When are you posting the closeups you took of the roof?

Seems like they found the problem. The EDIS module was crushed. It was on the front, behind the headlight, on the passenger side that got crushed. It cost $385.00 new. I figured I buy it new then used. You never know about these electronic components. I test it tomorrow.

I'd like to add some protection to my front bumper while the bender is available too. Does not have to be at the same time, but I thought it could be a good learning experience.

Brian not to sure on paking the RV on lawn...The city dosn't look to kindly at people parking on there lawn. It's against the law acually there:confused: No parking on the street from 3am to 6am either.:rolleyes: What can I say..it's a goofy city.:dunno:

So how much tube to we need?

100 ft for each of the 3 explorers and maybe 60+ for the 2 Rangers.

440-460ft total?

2 explorers, I'm not doing mine yet.

2 explorers, I'm not doing mine yet.

Mine, Jeff, and Brian.....

Your just a worker at the party! :p:

Right you are Kenny. :D I went off Matt's list and forgot about Brian...sorry Brian. :(

I am in as manual labor;)

I'd like to add some protection to my front bumper while the bender is available too. Does not have to be at the same time, but I thought it could be a good learning experience.
Come on up here with some tube. :thumbsup:

Ignition module behind the fender (why am I not surprised? I suggested this earlier)!! Dont buy new, they never go bad on these gen II trucks.

If I was coming to the party I would figure these cages would likely get tack welded in place for now, and as time allows some good beads layed down, but I would think each of you could do the final welding at a later date?

Man I wish the BII was in CA, a cage is my next project and I could use some team work on this sucker!

You guys need to make some metal plates with the So Cal club name laser cut in them and install one on each of these cages :)

I gave Totten a call.

For HREW 1 1/2 .120 wall $1.57 a foot:D

They come in 20' or 24'

BTW, you could save some weight and use 1.5" tube for portions of the cage that isn't critical..

When are we getting the tube? I might be in...and if I am, I'll only need enough to fill this.

Maybe we should have two cage building parties, the second one at my house. My Yuppie neighbors would love it. I have plenty of room for four or five Explorers in my back yard.:thumbsup:

Well if Steve's dad's place falls through... we can have it here. :D

When are we getting the tube? I might be in...and if I am, I'll only need enough to fill this.

I got a Sawzall! :D

I have a Craftsman rec saw, and my flux core welder.

I talked my parents, and they said they think they'll have room for the motorhome Brian:D


So are we going to do this our weekend we were going to big bear?

you guys need to take the measurments so you can build other cages late and sell them to others on the site. LOL

I talked my parents, and they said they think they'll have room for the motorhome Brian:D


So are we going to do this our weekend we were going to big bear?
Thank them for me! I can go on that weekend or any weekend this month, since I have them all off and nothing to do. This is one of the few mods I don't think the wife will complain about, since it will save her butt too if we roll again. And it isn't going to cost that much, considering.

I gave Totten a call.

For HREW 1 1/2 .120 wall $1.57 a foot:D

They come in 20' or 24'
How about DOM in that size? Thats a good price though. :thumbsup:

How about DOM in that size? Thats a good price though. :thumbsup:

I'd say at least twice that, if not a little more. When I bought my tube for my steering from them I bought a 20' or 24' piece of 1 1/2 .250 wall DOM and it was $146 bucks or something.

Yikes :eek:

I have no problem with HREW as thats what my front bumper is made of. It bent fine, and has held up very well even though its only 11ga. Just figured it was a good question to ask. ;)

They also have HREW in 1 1/2 .180 wall. It can't be to much more I wouldn't think, but your adding another 90lbs to the truck:rolleyes:

.120 is 1.77lbs per ft.
.180 is 2.63lbs per ft.

:D :D :D :D :D :D :D :D :bounce: :bounce: :bounce: :bounce:

When are we getting the tube? I might be in...and if I am, I'll only need enough to fill this.

Froader make your doors like this!

I'm going to make them like firezapper's

I'm going to make them like firezapper's

any pics

When you move Chris we will have to have a cage party over here and ill cut my doors like that. I like them.

any pics

http://www.explorerforum.com/forums/showthread.php?t=159807&highlight=3%2F4+doors

WHITE RHINO's lower cut is pointless. He can't get his legs through that. Plus his doors still open. :confused:




Any further on deciding when you guys are getting the tube?

Yeah but he still uses the door handle.

Wait a min. I think im to short to do doors like this. Its funny with the doors open much less with some cut off doors.

Yeah but he still uses the door handle.

So does FireZapper.

Back to the cage building party...

Any further on deciding when you guys are getting the tube?


Well we all need to deside on some things.

1. WHEN? I think we kinda all agreed on April 14-15th Right?

2. How much tube do we need and What are we using?


I don't mind ordering all the tube. Everyone can pay pal me the money or just give it too me when we meet. Once I know what we are using and how much I can get a quote for the whole thing.

Also again if anybody wants to start early..say friday, I'm good with that...just need to know so I can ask for the day off.

Also It may be a good Idea for some of us to meet before hand so we can discuss design. That way we are not all trying to figure out what were doing and wasting half a day of building.

Examples:

1.On mine, Jefe and Daves, me and Jefe discussed running the A pilar down the side of the dash, so the fuse box will need to be moved. I'm fine with that and will look into it this weekend, but is Dave ok with this?

2. on the explorers what all are we removing? Everything? or what? Like the cargo area, the side pannels? I was thinking about this, if you had to replace the cargo glass (like Tom does) you would not be able to get in there with a cage and the interior in the way.

Things like this.

I'd maybe leave the interior in yours while you guys work on Jeff's. That way you can see where things like.. THE BACK SEATS will be. So you don't get everything in and welded to find out the seats will no longer bolt in or something. :p:

Here is how I can see it working out. Just a few ideas.

Froader and I will use the same A piller as we have the same dash.
Jefe, stic-o, and DB1 will use the same A pillar

My B pillar and DB1's C pillar will be the same

Jefe and stic-o could pretty much bend up the same exact cage. The b pillar back might even fit Froader's as well by just leaving out the D pillar if he chops the top.

DB1 might be able to use the same B pillar as Jefe and stic-o

Just bumping this from the first page, it seems like good info. Matt had his thinking cap on. :thumbsup:
I'm (obviously) not getting a cage built, but my thoughts are, you guys should try to have as much design commonality as possible, agreed in advance. Fer instance, the 3 or 4 hoops, and a few tubes to connect them. Have getting that much tack welded in place be the goal for the weekend, for all involved.Then anything anyone wants that's different or extra, do that at the end of the weekend, or another day, or even on your own.

hrew 1.5 120 works for me. I just measured mine out and it looks like I could probably skim by with 40ft. I would be pushing it though. Get me 60 though cause others may need some extra for miss bends or what ever. I can always use the extra for something else later.

Don't forget about floor board plate as well.

As Section mentioned it might be a good idea to bring seats so we can make sure the will fit. They come in and out easy.

We all may want to go in on 1 stick of 1.25 120 wall as well so we can cut it up to sleeve any splices we may have to make.

Now another question.
Has anyone ever completly gutted there truck down to just the metal? How much hotter/ louder is it when done this way? Does any of that roll on bed liner stuff help or is it just a waste. If I complely gut my interior especally the head liner I can probably gain more head room on the b pillar which I will need all I can get. The door panels are goners so I wont have to worry about them. Maybe even the doors as well. Maybe we can bend some up over the weekend as well.

I still haven't measured for the tube i'll need but I'll post it up tomorrow morning sometime. I'll help out where I can on other peoples rigs as I only plan on getting the big hoops done then I can finish it up at my house.

And just in case some of you missed this in an earlier post:D :
Found these universal mounting plates on the A&A mfg. site...4"x3"-3/16" thick with (4) 3/8" holes $2.45 ea.
http://www.aa-mfg.com/pdshop/shop/item.asp?itemid=995


Who's bender are we using Jeff's or mine...doesn't matter either way for me.
I've got these tools I can bring:
Tube notcher
4 1/2" grinder corded and cordless
Corded and cordless drill
Bench grinder w/belt & disc sander attatchment mounted on pedestal
14" abrasive chop saw
Recip. saw

I'll help out where I can on other peoples rigs as I only plan on getting the big hoops done then I can finish it up at my house.

I'm in the same boat. I'll have Winter weld mine up. :)

I have heard that with no inerior it is alot louder, I noticed a big diference just taking out the padding in the cargo area.

If I gut my truck everything will be at my dad's so it will be nothing to just go grab a seat and see if it fits.

As far as tools, at my dad house we have.

Drill Press
Bench Grinder (needs a new wire wheel on the one side)
Plasma Cutter
Welder (Stick and wire)
gas torch
sawzalls
drills
air compressor
14" cut off saw
grinders 4" and 7"
engine hoist
floor jacks

and I'm probally forgeting stuff.:rolleyes:

Well, I may have to attend - doing my part as "concerned bystander"

2. on the explorers what all are we removing? Everything? or what? Like the cargo area, the side pannels? I was thinking about this, if you had to replace the cargo glass (like Tom does) you would not be able to get in there with a cage and the interior in the way.
I've already removed the cargo area panel on one side, and planned to remove it from the other side before the cage. I was planning to keep everything else though.

I have heard that with no inerior it is alot louder, I noticed a big diference just taking out the padding in the cargo area.

If I gut my truck everything will be at my dad's so it will be nothing to just go grab a seat and see if it fits.

As far as tools, at my dad house we have.

Drill Press
Bench Grinder (needs a new wire wheel on the one side)
Plasma Cutter
Welder (Stick and wire)
gas torch
sawzalls
drills
air compressor
14" cut off saw
grinders 4" and 7"
engine hoist
floor jacks

and I'm probally forgeting stuff.:rolleyes:

forgot a BFH

forgot a BFH

True, True......

Froader make your doors like this!


I'd be afraid my leg might fall out on a rollover.

That’s what they make leg restraints for!:D

I was out this morning measuring for the tube i'll need and realised I had all this 1.75" tubing that matt got for me so I think I'll use that for the B-C pillars and all the supports connected to them. As for the tube forward of the B-pillar, i'll use 1.5". So what i'm trying to say is that looks like i'll be building my own cage since there's no way I can haul 15 foot lengths of tubing in the Ranger but i'll still come to help out.

http://www.explorerforum.com/forums/showthread.php?t=159807&highlight=3%2F4+doors

WHITE RHINO's lower cut is pointless. He can't get his legs through that. Plus his doors still open. :confused:
Maybe he did them like that so he could see the where the front tire is without sticking his head out the opening.
I was out this morning measuring for the tube i'll need and realised I had all this 1.75" tubing that matt got for me so I think I'll use that for the B-C pillars and all the supports connected to them. As for the tube forward of the B-pillar, i'll use 1.5". So what i'm trying to say is that looks like i'll be building my own cage since there's no way I can haul 15 foot lengths of tubing in the Ranger but i'll still come to help out.

Maybe you could borrow a flatbed trailer, or hang them over the roof.
Oh, now my Dad, Sarah and Rossana all want to come up and help build cages. I don't know how much help they would be, but Sarah needs to learn her way around metal anyway.

Also, instead of building a hoop for the 'A' pillar, you could:

1) halo it
2) build it out of 3 pieces.

Also, ask yourself if how well you want your windshield visors to work.. in DWD's cage, they are still functional.

Also, ask yourself if how well you want your windshield visors to work.. in DWD's cage, they are still functional.

Good point. In my cage the front tube goes under the visor and they were functional.

Also everything in the dash was funcional including glove box. Biggest problem was releasing the emergency brake.

Mine was haloed, sure made things easier since it's hard to find a table big enough to get the angles on the same plane. I'm finally home and i'll get some pics today of my a pillars if it will help anyone.

Yea, that front hoop is tricky. It took 3 tries to get one for my zuk that was correct.

It's way easier to build it up from 3 parts than to make a hoop.

Mine was built by first bending up the B pillar hoop, then adding a D shaped halo coming off the top of the B hoop, then the A pillar bars come down off the halo.
Granted mine is all extenal, but the concept is the same.

Bill, if you look, yours is basically all 1 dimensional bends - everything is in the same plane.

The 'A' pillar is not - it's at least 2 planes, maybe even 3 planes, and that can be very difficult to do if your not used to bending tube ALOT.

I snapped a couple of pictures just in case it helps. I think it was Jefe that said something about cutting the door panel to make room for the A pillar and access to the fuse panel, so here's what i have.

I had a Idea... OK stick with me here:rolleyes:

So you build the B pilar and the a hoop tords the windsheild then run your two braces to the floor.

Then C pilar to D pilar box. This way you slide it out and do all your welding.

Then after front section are done, weld your supports B to C.

Also I could go snag a headliner from the junk yard so we would have a roof pattern to use.

I think both me and jefe want to run our cages as close to the body as we can.



So what's the deal..

Who's in? and do we have a date?:dunno:

I wish I had the money and the equipment to build a cage in my rig. I have been wanting one sence I decided to lift it and sence I get pretty crazy on the side of hills hehe:D ;) I do know how to bend pipe though. I used to bend steel ipes to make green houses when I lived in oregon a year ago. I used to have to do it manualy on a table jib cause I was bending them faster that way then the machine could do it.

Ok Guys ...I'm building with out you!! :D

http://www.explorerforum.com/photopost/data/500/medium/Roll_cage2.jpg

http://www.explorerforum.com/photopost/data/500/medium/Roll_cage.jpg

See it's helpful to have a Teacher as a wife. :p:

Ok Guys ...I'm building with out you!! :D

:wtf:

:crazy:



I DO like the red though :D

Ok Guys ...I'm building with out you!! :D


Let's see.. Fuzzy dice, furry dash, now a carpeted roll cage..

:eek:

:confused: I snapped a couple of pictures just in case it helps. I think it was Jefe that said something about cutting the door panel to make room for the A pillar and access to the fuse panel, so here's what i have.
Yeah, what he said.. I like this because it saves most of the leg room when entering / exiting. I need to maximize the interior space in mine, because I am not a small person.
Let's see.. Fuzzy dice, furry dash, now a carpeted roll cage..

:eek:

You got something you want to tell us, Stic?????:eek: :confused:

Well I was sitting in bed, last night and I looked over at my wife and said, "do you still have any of those pipe cleaners?";)




http://www.pirate4x4.com/forum/images/smilies/laughing.gif

Needs more triangulation!:p:

you wont be needing these:

http://cmwraceparts.com/images/kirkey/KIR99000.jpg

I'm out for a cage, but I'll still be there to help out.

So Dave is building his own...

Colin is broke.... (I can relate to that:rolleyes: )


So we're down to..

Jeff
Matt
Brian
and myself.

Correct? 4 trucks, with 3 being pretty close and a reg cab. this should go pretty easy.

So 360 ft or tube?

Did I miss anything? I plan to go pick up some floor plates this weekend.

Correct? 4 trucks, with 3 being pretty close and a reg cab. this should go pretty easy.

So 360 ft or tube?
Sounds right to me. I'd grab 400 ft though in case of screw-ups. And if it happens that we have too much, we can always pawn it off on one of the others that needs a cage. ;)

I'm ready to pay in, just give the word.

And are we upgrading a bender to hydro? Someone have a link on how-to? I can get mine setup ahead of time.

And are we starting Friday? I'm up for that. Just gotta ask for the time off soon.

Where are you guys building these? Any room for a Dodge/w camper over there for an overnighter, or a nearby RV park? I'd like to come over and photograph the event as well as learn something, and help out where needed:D

Jefe That's what I was thinking too. Best to be on the safe side.;)

I'm up for Friday, I just have one hang up, and I will not know till the last miniute. I have Jurry Duty that week.:(

Rick as for space for the Truck and Camper... I'll find out. I know my dad is talking about getting a gate put in this weekend so we can move more cars around. There is already 4 on the backyard grass:rolleyes:

Did I miss where a certain weekend was picked???

Cool that you're shooting this, Rick.

Someone should make the webcam idea happen. :D

i'm in depending on the final date

Did I miss where a certain weekend was picked???

Cool that you're shooting this, Rick.

Someone should make the webcam idea happen. :D

I think it's the Tiki Farm weekend, April 14th?

Jefe is the A/V tech guy. :D

I'm up for Friday, I just have one hang up, and I will not know till the last miniute. I have Jurry Duty that week.:(
Oof :(

Did I miss where a certain weekend was picked???
Yes. We're doing this rather than Big Bear the weekend of April 14th.

Jefe is the A/V tech guy. :D
I'll pass the webcam duty off to John. :D He already said he'd be there, and I'd much rather be getting my hands dirty than getting a webcam running. :p:

I'll pass the webcam duty off to John. :D He already said he'd be there, and I'd much rather be getting my hands dirty than getting a webcam running. :p:

There house is all set up for Wifi. :thumbsup: and they are on Cable so it should not be to slow.;)



Rick, My mom said she is going to talk to her neighbor to see if she can park there motor home there for a day or so. If not she said she has a extra room you could stay in. Then you could just cruise out in the Mach 1. :D

I am in.

What about getting one stick of 1.25 .120 wall tube so we can sleeve any joints that we have?


Also will there be room for my truck and trailer? Or do I need to drive the ranger up there? Tracy and I also might need a place to crash somewhere if possible so we dont have to do the long drive each day. I will know more in a bit if we will though.

Jefe I will try to find some links on pirates and post them up about the air over hydro.

Jefe

http://www.pirate4x4.com/forum/showthread.php?t=217928&highlight=air-hydro

http://www.pirate4x4.com/forum/showthread.php?t=21935

Ill try to find more later as well.

Matt,

I think we will be out of room for sure. The city will not like tent's on the front lawn:( and the backyard is full of cars:p: LOL

I talked to the wife and she said it would be cool if you want to crash at our place for a night.;)

Or my other thought was to get the Ranger done first, so if you wanna take off saturday night you could.


I think we should do a potluck for Saturday night too...Just like T-haven:thumbsup:

Sounds good Steve. I will keep you posted on how my end works out. Worst case is do the ranger Saturday then Sunday I can come back just with my Chevy.

here is another air hydro thread.

http://www.pirate4x4.com/forum/showthread.php?t=455001&highlight=bender

Coupon for the ram.
http://www.pirate4x4.com/forum/showthread.php?t=565188

Im down to help out if i can and just hang out. I dont need a cage, but maybe i can convince someone to fab up a front bumper??? If thats ok let me know and ill be there and let me know what id need to bring.

HF 8 ton air/hydro jack has been bought. :thumbsup:

Very Nice Jefe! :thumbsup: If you need me to pitch in some money for it just let me know, or we can just subtract some from the metal when I order it.

Jefe, I'm going to plan to take the 13th off. I start Jury Duty On the 9th so hopefully I'll have served my time by then. What sucks is I already postponed it once, so they will not let me do it again :(

Very Nice Jefe! :thumbsup: If you need me to pitch in some money for it just let me know, or we can just subtract some from the metal when I order it.
Well if it works great, I don't mind having paid for it for my bender. If it doesn't work so hot, I expect to be fully reimbursed, including mileage and time off work to go pick up the last one in stock in Simi Valley. :p:
I did get a 2 year unlimited warranty on it. Knowing Harbor Freight, I'm pretty sure that was a safe investment. ;)
I'm going to have to go pick up some steel to make a frame for it, as I don't think I have enough spare steel. :(

Jefe, I'm going to plan to take the 13th off. I start Jury Duty On the 9th so hopefully I'll have served my time by then. What sucks is I already postponed it once, so they will not let me do it again :(
Ok, I'm taking friday off and we'll hope it all works out.

Also, I mentioned earlier that I was planning to make my B-pillar (and possibly C) out of 1.75". Just a little extra beef where it won't be in the way. On the other hand, I don't want to screw up our mass-production operation. Anyone else with me? Just want to get an answer before we order everything.

My cab is already small enough. Im going to stick with 1.5 thoughout.

Does anyone else think we should pick up a stick of 1.25 tube? We can use it to sleve splices or as corner guusets as needed. I think it would be a good idea.

Jefe to bad I am not closer I have all the steel and casters to build the cart I just dont have a way to get it to you. Ill toss you a few bucks as well for the ram and bender use.

I also have a welding blanket as well that I will bring. That way we can maybe cover the dash and not get any burn marks.

Jefe I was looking at the truck and I think for the "A" pillar we can get away with out touching the fuse box. We just run the tube right in front of the opening at the edge of the dash. That way everything will still be accesable.

As far as tube, yes Matt we'll grab a piece of 1.25. How thick you want it? .120 as well?

and 1.75 for "B" and "C" is good for a very small price differance I'm sure it's worth it. So lets plan for all 3 Ex's using that.

So..

120' 1.75"x.120" wall
280' 1.50"x.120" wall
20' 1.25"x.120 wall


Does that sound right? Or should I do...

140' 1.75"x.120" wall
260' 1.50"x.120" wall
20' 1.25"x.120 wall

Once I know I'll call and get a price on all of it. When I go to order it, (once we get closer) I'll plan to have it dropped off Friday the 13th (oooowwwe Spokey!) morning.

Whatcha all think?

Ok, deleted my last 2 posts and condensed them to one, less confusing post:p:

Won't HREW tubing be hard to sleeve with the weld line inside?

Steve, can you put me down for one stick of 1.5" HREW...thanks:thumbsup:

120' 1.75"x.120" wall
280' 1.50"x.120" wall
20' 1.25"x.120 wall
That sounds good to me.

I went over to Johns and looked through the steel pile. Seems I've got 8' of 2x2x1/4 and 10' of 1.75 tube so that should be enough to fix up the bender. An d I made a list of hardware needed, so between the next two weekends the bender should be ready to roll. :thumbsup: The big question is do I bend up the legs before I take it apart, or after its setup for hydro and sitting on the ground. :confused:

I will also do an inventory of what hole saws I have for my notcher that are still good.

Dave, No problem;) That's a good point about the tube...do you think 1 3/8's would work?

Also with in 5-10min is a Harbour Freight, and OSH and Home Depot, for anything we may need that weekend at the last minute.

Wow, sounds like quite a party. If I'm not out of town I'll go on Satuday and hang out with a helping hand. This is awesome:thumbsup:

The 1.5 will sleeve 1.75 hrew fine. I did this on my lumber rack I just built for my Chevy. I see no reason why 1.25 would not sleeve 1.5 as well. A 1.5 .120 wall tube should have an inside dimension of 1.26". That leaves it a bit of slope right there. If the seam still makes it to tight just take a grinder with a cutting wheel and cut a small groove in it and then it should slide right in.

What compressor are we using? I was using our Husky 32gal 5.5 peak HP to extend the ram, and a no-load full extension would get it to cycle. It would keep up once on, but still, thats a lot of air. :eek:

And what are we gonna do for food?

And what are we gonna do for food?

Dr. Pepper thats all we need. :D Maybe BBQ up some hamburgers or something like that. Sounds like there will be a fair bit of people there so Im sure some one can get grill duty.

Dr. Pepper thats all we need. :D
Obviously. :D I just don't want all of our helpers to go hungry. ;)

What compressor are we using?


:D If we get it working tommorow, I'll take a pic for ya;)

I think it will be big enough...It's only a 120 Gal or so. :p:



as far as food, We got a BBQ, it probbally would not hurt to bring a extra propane tank though...don't want to run out.

New rule! If you come...you must bring Food or Drink! :D

bought the new pressure regulator for the compressor 2 days ago. Stic-o and Norm (that's his dad's name BTW) will install on Sat. The compressor came out of a BMW dealership very quiet and hopefully very tough! it will run 90 psi minium all day.

I have no problem running the grill as long as someone brings something to grill! hint hint! lol:p:

I can bring meat and grill up my world famous carne asada:thumbsup: If other people want burgers and/or hot dogs we can grill that up too but i'll bring carne. Just need a head count of who wants some so I know how much to bring.

As for power tools, are we pretty much covered or should I bring anything from the list I posted?

Carne sounds good. :thumbsup:

And the bender is getting close:

I'm in for sure on those dates:D
I'm glad you guys know what you are doing, because when you get into it, it seems you are speaking in a completely different language. I am going to have to watch and learn on this one.

The hydro bender works. :cool: I bent the legs up testing it out, but still need to brainstorm how to attach them while keeping it semi-portable and easily storable.

The hydro bender works. :cool: I bent the legs up testing it out, but still need to brainstorm how to attach them while keeping it semi-portable and easily storable.
Put wheels and a trailer hitch on it!

Ok, I got a quote on the Metal.

1.75x.120 wall $1.75 per ft
1.50x.120 wall $1.57 per ft
1.25x.120 wall $1.27 per ft.

So here is the brake down for everyone. We're adding 40.ft extra of 1.50 for screw ups, and 20ft of 1.25 for sleveing. I divided this by the four of of us. Dave is just grabing a stick for his project.


Steve
(40ft x1.75X.120) $1.84 ft.=$73.60
(70ft x1.50X.120) $1.57 ft.=$109.90
( 5ft x1.25X.120) $1.27 ft.=$6.35
Total $189.85

Jeff
(40ft x1.75X.120) $1.84 ft.=$73.60
(70ft x1.50X.120) $1.57 ft.=$109.90
( 5ft x1.25X.120) $1.27 ft.=$6.35
Total $189.85

Brian
(40ft x1.75X.120) $1.84 ft.=$73.60
(70ft x1.50X.120) $1.57 ft.=$109.90
( 5ft x1.25X.120) $1.27 ft.=$6.35
Total $189.85

Matt
(70ft x1.50X.120) $1.57 ft.=$109.90
( 5ft x1.25X.120) $1.27 ft.=$6.35
Total $116.25

Dave
(20ft x1.50X.120) $1.57 ft.=$31.40
Total $31.40

Total
(120ft x1.75X.120) $1.84 ft.=$220.80
(300ft x1.50X.120) $1.57 ft.=$471.00
(20ft x1.25X.120) $1.27 ft.=$31.40
Total $717.20


If everyone is good with this, You guys can paypal me the money, and I'll get it ordered.

They have it all in stock so we are good there, the other thing we need is floor plates, and I can pick those up in the next week or so, and you guys can pay me for those when we do the cages. I think jefe is the only one that has some already..correct? Also need a count on floor plates for matt?

can i jump in on this still :(

I think we're going to hold this at the 4 trucks in already, Otherwise we'll never finish in a weekend.

They have it all in stock so we are good there, the other thing we need is floor plates, and I can pick those up in the next week or so, and you guys can pay me for those when we do the cages. I think jefe is the only one that has some already..correct? Also need a count on floor plates for matt?
I went and found my plates, and they are 3x3x3/16". I'm thinking they are a bit smaller than I want to use. :rolleyes: I was thinking more like 4x4" or bigger. What if we got some 6x3/16" flat stock and plasma cut it for each location? Or are you guys wanting to bolt the cages in? If we bolt in, then the pre-punched will be faster. Anyway, I've got 20 of those plates if anyone wants some.

Steve, what's your paypal email?

I think we're going to hold this at the 4 trucks in already, Otherwise we'll never finish in a weekend.
I have to agree with that. This is going to be a lot of work. However, once we get it right and document it, any future cages should be cake.

Put wheels and a trailer hitch on it!
Well, its already hitch mountable, no wheels needed. But it sticks out 6' off the back. It needs legs though, because even in Johns hitch its only 28" high, so if we worked it like that all weekend, we'd all have bad backs. I'm shooting for a comfortable 34-36".

Steve, PM me your PayPal addy as well...unless you post it up...and i'll send you the money this week.

I went and found my plates, and they are 3x3x3/16". I'm thinking they are a bit smaller than I want to use. :rolleyes: I was thinking more like 4x4" or bigger. What if we got some 6x3/16" flat stock and plasma cut it for each location? Or are you guys wanting to bolt the cages in? If we bolt in, then the pre-punched will be faster. Anyway, I've got 20 of those plates if anyone wants some.

Steve, what's your paypal email?

I would rather just weld mine right to the floor, since its so much stronger, and faster, and I don't really see a reason to have it be a bolt in application. I vote for the flat stock, but does someone have a plasma cutter, cause those things are a blast to use.

Steve, PM me your PayPal addy as well...unless you post it up...and i'll send you the money this week.

DITTO!

I'm starting to get all excited about this, its gonna be a fun weekend, and is something I have been wanting to do for a few years now, and especially after I rolled it. I got some quotes on installing a cage in the Explorer, they range from $1,200 to $2,000. If I can get one in for under $300, plus a lot of elbow grease, count me in!:p:

I would rather just weld mine right to the floor, since its so much stronger, and faster, and I don't really see a reason to have it be a bolt in application.

Why not do both weld it in first, then when you get time bolt it in.

Why not do both weld it in first, then when you get time bolt it in.
I would do that for tow hooks and such, but I have had my sliders welded to the frame, in the same manner we are doing here, for several years now with no problems. And they get used! I don't forsee any problems with a weld in cage. I guess if one is inclined, they could bolt them later.

Why not do both weld it in first, then when you get time bolt it in.
If its welded in, whats the point of adding bolts? :dunno:

i dunno

Cool :thumbsup:

Paypal is:

a-sboggs@sbcglobal.net

Just need to here from matt.;)

I'm fine with welding. Dad's got a plasma, so we can just cut as we go. There is a local metal place about 2 miles from my dad's. We can just go pick that up friday, or again I can head over to IMS one morning before for work.;)

money sent. Don't be buying something else with it. :p:

If its welded in, whats the point of adding bolts? :dunno:

adding a plate under the body to strength it, to help prevent tearing of the body when a shock occurs..

adding a plate under the body to strength it, to help prevent tearing of the body when a shock occurs..

You know I was thinking this, use the bolt on plates and sandwich the body with them? :rolleyes:


But I could see how acut and fit thing would be way easier on the inside anyway


Hey jefe, Are you still planning on going to Fabulous Ford's the weekend after the cage work? I'm out I'm sure my truck will still be in pieces then. :(




By the way, I was thinking of going over and getting Matt and Jefe a special treat for the party;)

http://www.sodapopstop.com/images/products/large_10.jpg

You know I was thinking this, use the bolt on plates and sandwich the body with them? :rolleyes:


You could take it a step further and do something like polyperformance's cage tie-in kit:
http://www.polyperformance.com/shop/product.php?productid=433&cat=551&page=1

Except you could source the urethane bushings online cheaper and just make your own tabs or also buy some online and of course the tube is a no brainer.

adding a plate under the body to strength it, to help prevent tearing of the body when a shock occurs..

A plate of a different size, from what I've heard, is recommended. Either larger or smaller.

So i just want to get this right. i read that you are gonna use HREW tube and not DOM. I was trying to find DOM for my radius arms and it is rediculously expensive everywhere i look. So if HREW is safe for roll cages, will it be alright for suspension parts and bumpers then also?

adding a plate under the body to strength it, to help prevent tearing of the body when a shock occurs..
But nearly all the force of a roll will be pushing against the body, not pulling away from.
A plate of a different size, from what I've heard, is recommended. Either larger or smaller.

That makes sense.

:p: After watching Tom R's rig go over, and then inspecting the cage and finding no buckling, and no deformation of the weld in plates, or the sheet metal it was welded onto, I don't really see a problem with just welding them in. I really don't think you will get a more severe roll than that the way we wheel. I could see doing something like that tie in kit, if I was DannyBoy.

you have to think that when you roll and the top of the cage hits the ground that it will be pushing on the side thats in the air and pulling on the side thats on the ground trying to peel it away from the body. I would imagine that if they make cars and use the body to act like a frame and just bolt the subframes to them, they would hold up without any problems. i guess it would be added insurance for those "just-in-case" situations.

you have to think that when you roll and the top of the cage hits the ground that it will be pushing on the side thats in the air and pulling on the side thats on the ground trying to peel it away from the body.
Its not trying to peel it away from the body, the cage absorbs the shock and stress of a roll over, keeping the roof from squishing the passengers.

These need to be safe enough for highway driving (in case of an accident) speeds as well. Not all of us get to tow to the trails.

I think at this point we just would like to walk away alive. and a plus would be to drive the rig another day.

Honestly my biggest fear right now is not rolling out off roading...it's the idot who cuts me off on the freeway and sends me into a action that the truck may not recover from on 4 wheels. Sense this is still my DD for now:rolleyes:

A plate of a different size, from what I've heard, is recommended. Either larger or smaller.

plus you need radius the corners; square corners will tear the sheet metal apart.

The forces in a roll over are incredible, and they are in all directions.

The #1 reason for the plates is to attach the cage to the body.

The #2 reason is to keep the tube from punching through the body in a crushing blow, ie a 180degree roll onto the roof, therefore trapping you between the cage and the floor pan.

Then you get into the discussion of attaching seats, seat belts - plus the cage to the frame discussions.

HREW for an interior cage is fine for most people - properly triangulated, it will hold up for a single use. The tube itself is protected against most impacts by the body. But then, in a good hard rollover, the vehicle body is probably toast anyway..

DOM is best for impact areas - ie, arm links and such. Even then, there is voodoo science involved in correctly sizing the tube (ie, a 2"/.120 wall DOM tube can be stronger than 1.5"/.250 wall DOM tube).

I think at this point we just would like to walk away alive. and a plus would be to drive the rig another day.

Honestly my biggest fear right now is not rolling out off roading...it's the idot who cuts me off on the freeway and sends me into a action that the truck may not recover from on 4 wheels. Sense this is still my DD for now:rolleyes:
I know the reaction to getting cut off is to swerve, but you have to force yourself to just take the hit, since it should keep you from the dreaded rollover on the freeway. I don't care how well you build a cage, if you roll it on the freeway, it will keep you alive, but the rig will be toast. I am just playing the odds and the odds are if you roll it, it will be in the dirt and at slow speeds.

I know the reaction to getting cut off is to swerve, but you have to force yourself to just take the hit, since it should keep you from the dreaded rollover on the freeway. I don't care how well you build a cage, if you roll it on the freeway, it will keep you alive, but the rig will be toast. I am just playing the odds and the odds are if you roll it, it will be in the dirt and at slow speeds.

Actually I've done some pretty crazy thing in that thing on the freeway. It's the guy that hits me shooting for his exit from the fast lane that worrys me. or the guys that hits me from the side in a intersection, and tips me over:(

Actually I've done some pretty crazy thing in that thing on the freeway. It's the guy that hits me shooting for his exit from the fast lane that worrys me. or the guys that hits me from the side in a intersection, and tips me over:(

im worried about someone getting right under one of the rear tires. yeah that would sent it right over.

but does someone have a plasma cutter, cause those things are a blast to use.



Steves dad and I both have one.

If you need me to bring mine as well Steve let me know. Should I also bring my welder. I can probably bring my bosses 110v flux core wire feed it would make it easier for tacking stuff sence we will be welding them at home later.

Ok, I got a quote on the Metal.


Matt
(70ft x1.50X.120) $1.57 ft.=$109.90
( 5ft x1.25X.120) $1.27 ft.=$6.35
Total $116.25



Sounds good. Did you include Sales tax in these prices? Also what is the paypal fee so I can cover that as well. I dont want this costing you anything. Or should I just add 10% to it and call it good. let me know and I will send it on its way.



But I could see how acut and fit thing would be way easier on the inside anyway


What if we also ordered a 20' long piece of 6" wide 3/16 plate. Then we could all make our base plates out of that however we feel they will fit best.
I need 4 base plates for my truck.

Steve sence you are heading this up maybe make a list of tools that you want us to bring or things that you think would be nice to have that you are unsure if anyone has. There is no point in us having 5 welders there if we can only plug one or two in at a time.

Also a thing to consider is flapper, grinding, cutting wheels, chop saw blades, and other consumables we might need. Should we just buy them that morning and when then split the cost when we are there?

Matt 10% should be fine.

I think for the 6"x 3/16" we could just get it that morning, or I'll go get it ahead of time. This may sound weird, but the place I'm getting all the tube from....only has tube I think...no flat stock:scratch:


For the tools... I would say bring all the small stuff you want. I think we should be good on the welder, but I'll check with my dad first. He only has 3 or 4 of them. :rolleyes: A bunch of extra grinders and stuff will not hurt.

as far as consumables, I would like everybody just go ahaed and bring some that will fit there tools I would say. I'm sure most will be able to use on each others and what ever is left they could just take home again. Running back and forth to the hardware store takes up a lot of time. :rolleyes: Been there done that!

I'll bring my 110v flux core welder, it lives in the RV anyway.

I have a question about the interior. Should I just strip the entire thing out, including the headliner? Give me a list please...
Also I can't take the carpet out entirely because the shifters for the transmission and transfer case are bolted down on top of it, so what I will do is just remove the seats and push it around as needed. I will just throw the seats back inside for fit testing, since I think I have the only first generation. I would like to get as much interior parts back in after it is caged as possible, just to keep the noise down. The headliner is a must.

I'm planning to just keep the headliner & associated interior panels in place. It will be difficult to weld the cage up like that, but its nearly impossible to get the headliner in afterwards, from what I've heard.
So really, all we need to strip out are the seats and carpet, and the rear cargo panels.

I'm planning to just keep the headliner & associated interior panels in place. It will be difficult to weld the cage up like that, but its nearly impossible to get the headliner in afterwards, from what I've heard.
So really, all we need to strip out are the seats and carpet, and the rear cargo panels.

How about the front door panels? If we are going around the sides of the dash, the door panels will get in the way. I am for leaving as much stuff as possible, since it will be less work on the back end, but I am afraid of lighting my headliner on fire.:fire:

Oh, Matt, the flux core welders seem to spit a lot more than gas welders, so I don't know if they are a good idea to use inside the rig.
I'm trying to talk my Brother-in-Law into coming up with us because he loves fabricating and is a real good, clean welder.

I think I may put the seats back in after I take out the carpet. We will need them in to fit everything in right anyway. If not they will be sitting right there anyway. I think we'll find the first gen interior will be almost exsactly the same. My other question is the over head display... Not sure I will be able to keep it?:( If I can't keep it, I'll have a hole in my headliner, which means I mite as well get rid of the hole thing:rolleyes: Of corse this all depends where we run stuff. Also jefe what are we doing with seat belts? Did you plan to tie those in with a tab?, or do that later? I know we have those goofy adjustable ones on our B pillars they may get in the way. I aso have my overhead light where the B Pillar bar may go..:(

How about the front door panels?
True, but those only take a minute so :dunno:

but I am afraid of lighting my headliner on fire.:fire:
If you look at one of Tom's pics, they are using a piece of sheetmetal between the cage and the headliner while welding. Plus we'll have a couple of welding blankets to protect anything left in the rig.
For spot welding the flux-core welders will be OK. But I agree that you're not going to want to use flux-core to weld the cage up. You'd never be able to get the flux smell out of the interior, and the splatter wouldn't be good either.
Anybody have their welder setup for MIG besides me? I'll try to fit mine in my truck.

I think I may put the seats back in after I take out the carpet. . . . I aso have my overhead light where the B Pillar bar may go..:(
Someone needs to have seats, so that works. All of our seats are nearly identical. We'll work around the overhead console and dome light. I do plan to tie in the seatbelts, and you're right that the slides make it more difficult. The slides have a bolt at top and bottom that we should be able to tie into with a little spacer or something. It can be done later, as long as we keep that in mind. I'm not sure there's a reason to tie into the seatbelts though, unless you are also mounting the seat to the cage. :dunno:

I'm getting stressed over this and its still 2.5 weeks away. :confused:

Okay, finally got around to posting the pics of Tom's rig.
Side and roof damage;
http://www.explorerforum.com/photopost/data/2/Tom_s_Roll_1.jpg
Front windshield area wrapped around cage.
http://www.explorerforum.com/photopost/data/2/Tom_s_Roll_2.jpg
http://www.explorerforum.com/photopost/data/2/Tom_s_Roll_3.jpg
Interior and cage (notice stress / impact points are all undamaged);
http://www.explorerforum.com/photopost/data/2/Tom_s_Roll_4.jpg

Anybody have their welder setup for MIG besides me?


I know my dad has one that is set up for it, However we can not see to find out much info on converting it over. :(

Interesting Article, everyone may want to take a look at on cage building.

http://www.therangerstation.com/tech_library/rollcage.htm


Also, I forgot my dad's '69 Cortina has a simple cage in it for referance. It's just a B pillar hoop with supports.

I've got my 220v Lincoln that only takes a minute to switch over to MIG. Just have to reverse the polarity and it's good to go, not sure how much gas I have left though...should be enough for tacking.

How is everyone going about getting full welds at the joints around the roof areas? Extreme 4x4 had a good idea of using a hole saw to cut holes in the floor to lower the cage, weld, then plate over the holes.

My 220v welder is setup for mig. I can try to bring it if needed. I think a 110v fluxcore will be better for tacking with though. Sure will be easier to move around.

Dave I was thinking like you were about hole saw the floor to drop the cage. The other option is to cut the bottom 6" off the legs so it can drop down and then sleeve the joint. JR on pirate4x4 had a good write up about doing splices in tight spots.

Once my cab ends up like Rios is in the pictures above the cab will be getting cut off and tubed out.

Once my cab ends up like Rios is in the pictures above the cab will be getting cut off and tubed out.
Let's just save you some time and cut the cab off at the party. :p:

Let's just save you some time and cut the cab off at the party. :p:
Naw, we wouldn't want to be like the Texas crew. :p:

Let's just save you some time and cut the cab off at the party. :p:

I still like to be kind of highway legal for a little longer. We need more trailer trash in our group with completly un streetable rigs before I am ready for that. Besides what fun is it cutting up good sheet metal. Twisted metal is much more fun when it pops and rips the saw out of your hands.

Money sent;) :thumbsup:

So it's just Jefe and me for carne asada taco's? Any more takers?

Always up for Carne Asada!:D

http://www.youtube.com/watch?v=Yd9aj7X5f1Y

Thanks Dave;)


I like the Ideas of cutting the 6" and drop and sleve better I think;)

I'm sure we'll have some 1.75" left over that we can sleeve over the bottom 6". But that really means that we're back to fully welding the cages before we drive home unless we take the cage home unassembled. :rolleyes:

Im up for carne asada. You can tack it together then use a sawzall to cut the legs to drop it. then sleeve it after that.

So it's just Jefe and me for carne asada taco's? Any more takers?

Whoa whoa whoa Dave!!! You know I'm in for those. :D

Sent you a paypal. I hope I did the conversion of to Check Coruna right. :D

Steve, I am having trouble with my paypal account. Let me know if you received anything, or got it twice..

How is everyone going about getting full welds at the joints around the roof areas? Extreme 4x4 had a good idea of using a hole saw to cut holes in the floor to lower the cage, weld, then plate over the holes.
I have a good hole saw set I can bring.
Oh, and Sarah and I are up for the carne tacos.

Money sent;) :thumbsup:

So it's just Jefe and me for carne asada taco's? Any more takers?


I'll take some, just ship it to me :D

mmmmmmmmmm carrrrrrrrne you have to roll you R's carrrrrrrrne. Or just walk into mexican restarant and say "dos asada taco's mi amigo".

Can I come down for lunch that day?

I haven't done 100+ MPH for several hours on the VFR for a long time..

:D

Steve, I am having trouble with my paypal account. Let me know if you received anything, or got it twice..

Brian,I have not recived it. I'll probbally order the metal Monday.




Also it apperars we may have a 5th truck...sort of...if call something that small a truck:rolleyes: I'm not going to complain though, it's a small price to pay for the use of the driveway, and tools.:thumbsup:

Brian,I have not recived it. I'll probbally order the metal Monday.




Also it apperars we may have a 5th truck...sort of...if call something that small a truck:rolleyes: I'm not going to complain though, it's a small price to pay for the use of the driveway, and tools.:thumbsup:

Zukman’s Zuk I presume!

yes the zuk needs a cage too! rag top already has one but hard top needs one.

yes the zuk needs a cage too! rag top already has one but hard top needs one.

Is the HT removable?

Is the HT removable?

Nope! They made convertibles and hard tops. The hard tops just are'nt as common.

Can I come down for lunch that day?

I haven't done 100+ MPH for several hours on the VFR for a long time..

:D
Come on down, Tom, and bring that big brain of yours....we might need it.:confused: :rolleyes:

Okay, Steve this time I got a verification from paypal, so I think it worked.:thumbsup:

Okay, Steve this time I got a verification from paypal, so I think it worked.:thumbsup:


Got it!:thumbsup:

I'll order the metal monday;)

Come on down, Tom, and bring that big brain of yours....we might need it.:confused: :rolleyes:

I would need a place to stay.. It's either VFR, or fly into an airport.

considering I've already built one cage for an Explorer, that experience can be very helpful.

Add to your list of needed tools:

bungie cords and ratchet straps.

All lengths. Very helpful to pull the cage together and holding it.

Metal is Ordered!


http://research.soe.purdue.edu/ackerman50/images/thumbsup.JPG

So, can I get in on this?




























































:p:

See you guys on the 14th.

Colin....Your a day late on the April Fools Joke:D




What all does John need to set up the webcam? or just a connection?


Also My dad asked that If I would just PM the Address out. So anyone that is planinng to come, besides the obvious, please let me know.;)

What all does John need to set up the webcam? or just a connection?
I'll do it off my laptop, so as long as I'm in range of the wi-fi, that should work. And a power circuit, preferably one that doesn't have a bunch of tools and welders plugged in. of course we'll need a place to put the computer that we won't be throwing dirt and grinding bits at it.

Sarah and I decided to take a trip to Truckhaven this weekend. We are going out Thursday afternoon and going home Saturday evening, since Sunday is Easter and we have family commitments. We are going to camp up on the mesa near the spot from last trip, and do some mild wheelin. Plan on going to Sand Canyon and other scenic spots in the state park. Anybody up for a short notice trip?:thumbsup:

Check out this crazy.......

http://stupidvideos.com/video/stunts/uphill_in_a_4x4_crazy/

Check out this crazy.......

http://stupidvideos.com/video/stunts/uphill_in_a_4x4_crazy/
:eek: :confused: :eek:

He did the only thing he could to save himself rolling all the way down the hill, and totally pulled it off! Awsome:thumbsup:

I think he just created a new sport!

Freestyle Hill Climbing! :D


I'll bet he could not wait to get all the way down the hill to clean out his pants:rolleyes:



Just got the fax conformation;)

520ft of metal
952lbs.
$912.33

I guess I forgot about the state wanting there cut:dunno:

Just got the fax conformation;)

520ft of metal
952lbs.
$912.33

I guess I forgot about the state wanting there cut:dunno:
How'd we get from 440ft to 520? The zuki isn't going to take 80ft is it? :confused:

Sarah and I decided to take a trip to Truckhaven this weekend. We are going out Thursday afternoon and going home Saturday evening, since Sunday is Easter and we have family commitments. We are going to camp up on the mesa near the spot from last trip, and do some mild wheelin. Plan on going to Sand Canyon and other scenic spots in the state park. Anybody up for a short notice trip?:thumbsup:


Maybe i'll come out Sat. and do a run with ya:thumbsup: I'll let you know for sure tomorrow.

Just got the fax conformation;)

520ft of metal
952lbs.
$912.33

I guess I forgot about the state wanting there cut:dunno:
Did I send you enough cashola?? I rounded it up after adding 10%.

Maybe i'll come out Sat. and do a run with ya:thumbsup: I'll let you know for sure tomorrow.
Saturday would be good, but I would like to leave for home by early afternoon (famous last words). That is almost as famous as the fighter pilots............."Oh, SH*&!"

Brian, Don't worry about it...We can sort it out later. I ran into another issue anyway:rolleyes: Paypal only lets me take out $500 a month (unless I give my social) and I did it yesterday:banghead: Should have moved the money on Saturday, I got it covered though.;)



Jefe, My dad asked for 80ft...So that's what I orderded him...:dunno: I figure if we need extra, we can snag it from him! :D

Jefe, My dad asked for 80ft...So that's what I orderded him...:dunno: I figure if we need extra, we can snag it from him! :D
That is a great idea, talking your Dad into thinking he is getting a cage in the Zuk, when all you really wanted was a little extra tubing.......clever.........clever.:rolleyes:

I was just wondering where exactly truckhaven is located. I have heard a lot about it but am not sure where it is. I really want to find a kewl place to work out my suspension on my truck. I just lifted it aith almost 8 inches out front and 4.5 in back. I am going to lift the back up more I just need the break line and the shocks to do so.

I was just wondering where exactly truckhaven is located. I have heard a lot about it but am not sure where it is. I really want to find a kewl place to work out my suspension on my truck. I just lifted it aith almost 8 inches out front and 4.5 in back. I am going to lift the back up more I just need the break line and the shocks to do so.
Just do a search of this web site and you will find hundreds of threads, and directions.

I found a place with some good prices on cage accessories.:thumbsup:

They have the padding
1" thick 36" long /12 pack for $32.10
http://www.cdoc.com/rmsimages/15071_ct.jpg

and they have gussets..
Pack of 25 for $17.50
http://www.cdoc.com/rmsimages/7234_ct.jpg


http://www.cdoc.com/products.asp?str=2000-0089&name=Roll+Cage+Accessories

I found a place with some good prices on cage accessories.:thumbsup:

They have the padding
1" thick 36" long /12 pack for $32.10
http://www.cdoc.com/rmsimages/15071_ct.jpg


I found a place for padding too, the hardware store......;)

I found a place with some good prices on cage accessories.:thumbsup:

They have the padding
1" thick 36" long /12 pack for $32.10
http://www.cdoc.com/rmsimages/15071_ct.jpg

and they have gussets..
Pack of 25 for $17.50
http://www.cdoc.com/rmsimages/7234_ct.jpg


http://www.cdoc.com/products.asp?str=2000-0089&name=Roll+Cage+Accessories

Those look like the "noodles" we use in our pool:p:

Brian, I'm gonna take a pass on Truckhaven...i've got stuff to do around the house and the truck as well. It's supposed to be around 97 this weekend so stay cool out there.

I found a place for padding too, the hardware store......;)

Seriously, get the good stuff. The stuff that the hardware store sells does not have the offset centers, the microcells, and meets race standards.

Nothing like bumping your head into cheap padding..

It's supposed to be around 97 this weekend so stay cool out there.
Doesn't that mean its 97 at your house too??:confused:

Jefe I pulled a door pannel today. I think we may have a problem....maybe:rolleyes:

After pulling the pannel there is exsactly 1 1/2" between the side of the dash and the speaker once you pull the pannel. So if we are dead on...she'll fit perfect. But it's kinda cutting it close. Can't really push the speaker farther in, because the back of the speaker is already almost right up the glass when down.

Sorry about the pic's I took them with my cell in the dark..:rolleyes:

http://www.explorerforum.com/photopost/data/500/door_pannel.jpg

http://www.explorerforum.com/photopost/data/500/dash_to_Panel.jpg

I have been thinking about making flat metal door panels...looks like it would work..


Seriously, get the good stuff. The stuff that the hardware store sells does not have the offset centers, the microcells, and meets race standards.

Nothing like bumping your head into cheap padding..

Tom I found the right stuff! :D My noggin dosn't need anymore damage:(

Got this email from the dude I bought the flag pole from at TDS. They manufacture the "Oh S*&t" line of grab handles. I asked them about a group purchase since we will all need at least four of them eventually. I am planning on six, four for the front, two for the rear.

"As for the grab handles, we sell them for $39.95/pair. Many of our retailers sell them for more. Mastercraft sells theirs for
more than us and our handles kick their butts. I hope you've had a chance to see the quality in ours. We had them at TDS.
Since then, our dealers are ordering 12-20 pairs at a time. Crawl magazine is doing a product test with them at the Moab
Easter Safari right now as well.

What I can do for you on price, is extend the TDS discounted price of $35/pair. That's about a six pack of beer discount per
pair. With a rollbar building party, you may need a lot of beer."

http://racewerks.com/

I really like the soft handles for getting in and out of the vehicle. And in the rollover it kept me from wanting to grab around the rollbar which is a good thing. But my hand was pretty sore and scratched up because it is soft and difficult to brace yourself against and some glass got between my knuckles and the roll bar. So while 99% of the time I'd prefer the soft handles, I'm leaning towards welded in handles for that 1%.

I'm leaning towards welded in handles for that 1%.


That's what I was thinking, just order some 3/4" or something tube, bend, and then weld some on. Then you could always wrap them in baseball bat tape or something.



Like "B" not "A"
http://www.therangerstation.com/tech_library/images/grabhandle.JPG

Doesn't that mean its 97 at your house too??:confused:

Yes, but I won't be sitting in my truck on the trail roasting:D

He'll be on a noodle/cage pad in his pool. :D

Yes, but I won't be sitting in my truck on the trail roasting:D
Neither will we, I have AC in both vehicles.:p:

I will not be going with welded grab handles because I am worried about knocking myself out with them due to the limited space. And, I want to be able to move them around. The handles from Racewerks have a stiffener in the handle that is supposed to solve the smashed finger problem.

Jefe, are we going to have to move the gauge pods on the left "A" pillar?

I have another request that everyone wash their vehicle and clean out the inside because its much more pleasant working on a clean vehicle than one covered with Truckhaven dirt.:thumbsup: I am aware that cage building is a dirty business, but I really like the smell of freshly ground metal and welded steel, and not so much the smell of dirt.

Jefe, are we going to have to move the gauge pods on the left "A" pillar?
Yup. :rolleyes:

Yup. :rolleyes:
That's great, since I drilled some big holes in that plastic trim for the wiring. I guess we can get those roll cage gauge pods I saw on egauges.com, and the cage should hide the holes. Everytime I do a modification on the Explorer, it seems I have to change an existing modification.:rolleyes: :confused: :eek: :mad:

Would anyone be interested in doing the same thing in norcal? I have a 28x30 shop w air/110 & 220 mig/3 phase power but no bender (yet)

That's great, since I drilled some big holes in that plastic trim for the wiring.
Yeah, me too. :(

Would anyone be interested in doing the same thing in norcal? I have a 28x30 shop w air/110 & 220 mig/3 phase power but no bender (yet)

Where are you located?

I have a hydro bender, and it sits idle most of the time.. and when I loan it out, it comes with an operating manual.. Me. :D

Where are you located?



Ditto.

Would anyone be interested in doing the same thing in norcal? I have a 28x30 shop w air/110 & 220 mig/3 phase power but no bender (yet)


According to my super computer skillz you're located in Chico? :)

Where are you located?

I have a hydro bender, and it sits idle most of the time.. and when I loan it out, it comes with an operating manual.. Me. :D

Im in about 20miles south of chico, about midway between sacramento and redding. Shoulda put that in before :)

Im also looking for info on superlift 5.5 vs the james duff of the same height. to me the james duff looks MUCH better, but then again I havent used either so what do I know lol

Soo... Gridley?

Tom, when you did Kevins cage how did you guys weld the back of the tubes that are next to the body. I didnt see if you posted it or not.

actually richvale but very close to gridley.

actually richvale but very close to gridley.

Let's set something up! :cool:

I'm going to be busy for a bit, Its planting season for rice so I get to work short weeks only 12-16hrs a day 7 days a week but the nice thing is my shop has A/C!!! But I would love to set something up. :) I should know more monday about how long etc

btw I have a 24' enclosed, and a 20' flatbed trailer so picking up the materials wouldnt be a problem
Give me a call #530-882-4410

hmmm. if the nor cal thin happens i m will most likely be down :)

Looks like I will have friday off. Are you planning on starting friday or saturday morning?

Tom, when you did Kevins cage how did you guys weld the back of the tubes that are next to the body. I didnt see if you posted it or not.

I don't really remember how we did it.. I think we got as much as we could, and used sheetmetal + a welding blanket to do as much as possible without melting too much of the liner.

Yes, I'll lay odds there are points in Kevin's cage where it is not fully 100% welded.

Im in about 20miles south of chico, about midway between sacramento and redding. Shoulda put that in before :)

Im also looking for info on superlift 5.5 vs the james duff of the same height. to me the james duff looks MUCH better, but then again I havent used either so what do I know lol

I would do a solid axle conversion before I ever spend another dime on a superlift lift kit.

Been there, done that, got the pictures of bent pieces to prove it.

I would do a solid axle conversion before I ever spend another dime on a superlift lift kit.

Been there, done that, got the pictures of bent pieces to prove it.

Preach it brother. He speaks the truth. Plus there are far more SAS guys in cali now then IFS. Dont be in a protected class come to the majority.

Looks like I will have friday off. Are you planning on starting friday or saturday morning?

Jefe has Friday off, But I'm still waiting to find out. I have it off from work no problem, but I have to call in Monday morning for Jury Duty.:( Not sure if I'll have to go Friday. Everyone cross there fingers:help:

Ok I PMed the address to those that said they were coming. If you didn't get a PM and plan to attend, let me know so I can send you the address.

Also is Rick still coiming? I know he was thinking about it...:dunno:

Is Rios coming? Tom if you are let me know and I'll PM you the Address or maybe you and Bill want to come up together:thumbsup:

Davis? I'm gussing that's a little far for a bike ride:( But let me know.;)

Davis? I'm gussing that's a little far for a bike ride:( But let me know.;)

No, it's not too far for a bike ride.

I've done more in single day (Vail, CO to Oakland, CA - little under 23 hours)

But, I've got enough work to do here, including prep for the Hammers at the end of this month.

Alright, my interior is ready for a cage, how about everyone else?

http://www.jefethegreat.com/host_pics/IMG_0900a.jpg

J/K :D








Ok, ok, heres the explorer:

http://www.jefethegreat.com/host_pics/IMAGE_00073a.jpg

It took less time to to pull the 4 seats, carpet, center console, and tool box than it did to organize all the crap that I took out of it. :o Plus it was somewhat counter productive since I don't have anywhere to store all the stuff, so it all got put back into the vehicle. :rolleyes:

Is Rios coming? Tom if you are let me know and I'll PM you the Address or maybe you and Bill want to come up together:thumbsup:

Yes I'm going. I feel like a proud dad. Cage party is a result of me and Mrs. rollover. :D and Matts brilliant idea.

Ok good news and bad news...

Bad news: is I did not get a chance to remove my interior, and probably will not get a chance till Friday.


Good news: We now have some room for some tents:D :thumbsup: We we're able to move some stuff around and have room for about 2 or 3 tents. That way some of you driving for a distance can't just camp out.;) (sorry no bon fires though:( )

Let me know who plans to tent it.. so we don't over book;)

Yes I'm going. I feel like a proud dad. Cage party is a result of me and Mrs. rollover. :D and Matts brilliant idea.

Tom, I'll PM you the address

so ummm will you guys be building a few extra to sell to cover the cost of this? *hint* *hint* or just post lot of pics and stuff liek that since i'll be wheeling while your building

We are going to have a hard time just building the cages for us in this short amount of time. I personally have no plans to build cages to sell or anything else. This is a hobby for me and I plan to keep it that way. Anymore and it would be to much like work. Besides us all getting cages in our trucks I figure we can hopefully get others motivated to build cages as well. Also I figure by doing 4 cages we will be able to find the problems and solutions to them to help others after we build our cages. I have found little to no info on cages for rangers and explorers that show areas that are tight and areas where you have to do a give or take to make it fit.

Steve will there be room for my truck and trailer or do I need to drive the ranger up? Driving the ranger or towing it up will cost the same.

Steve will there be room for my truck and trailer or do I need to drive the ranger up? Driving the ranger or towing it up will cost the same.

I would just bring the ranger...With Brian motorhome and maybe more spending the night, we'll need all the space we can for trucks

RockRanger just take lots of pics fo the installs if you can so i can learn. i already see where mine is going to defer than your guys. i plan on moving the stock fuse box and rung the tube tho there and modding the dash bit.. i am to tall to lose space in the cab. Really wish i could what it live :) should be a hoot

Just got back from Truckhaven, and it was HOT!. Nights were nice though. Went all over the State Park doing easy stuff.
Now I have to clean up the Explorer and the RV, and gut the interior of the Explorer while working every day this week........ahhhh, maybe I didn't plan this so great.:rolleyes: :p: I figure I will clean out the RV on Monday, the Explorer on Tuesday, and maybe start on the interior removal. Should not be a problem (famous last words).
I will be up there on Friday early evening, if that is okay with your folks, Stic.
Maybe someone should start a Northern California cage building thread........hint, hint.;)

Oh, and that Diablo Dropoff that they say is only a down hill trail because its too hard to get back up, they are full of it. It was easier going up than coming down it!:p:

Ok how much are we taking out of the interior? Everything but the headliner? I started taking the back panels off and I'm thinking of just gutting everything... :rolleyes: It's a off road truck...don't really care what the inside looks like anymore...care more about my walking away...should something happen.:salute:

I took out seats, carpet, and all the plastics low enough to hold the carpet down. I really don't want to take out the headliner, and all the upper trim helps hold up the headliner. Oh, and as I just found, they help hold the door seal in place as well. I really don't care what the interior looks like either, but I do car how loud it is inside, and without the carpet its LOUD. I know the headliner provides noise insulation as well as thermal insulation.

Whats the schedule like? When should we be there, when do we need to be quiet, who else will be there friday?

Whats the schedule like? When should we be there, when do we need to be quiet, who else will be there friday?

Not sure yet... I just called on I'm on tap for Jury Duty tommorow, so hopfully it's over quick and dosn't extended to Friday.:rolleyes:

As long as I'm not ON J.D. friday, I plan to get there at about 7am. I want to be there when the metal gets there, and they like to drop it off early in the morning. We can probally go until dark if not a little later no problem.

I belive Matt is going to come up, and Brain is coming up Friday night, which I still need to double check on, but I'm sure it will be fine.

Brian...Friday night is Good! :thumbsup:

I'm working on triming the back pannels now. That way I can cut out the part that goes over the humps, and keep the outer top frame that keeps the headliner up. I'll end up opening the window hole some so if window removal is needed in the future, it will be easy to get at. Also plan to move the PATS brain... I thinking of behind the rear seatbelt...just don't want to put it a place where it could get crushed some how. That would be bad!:(

Right now it looks like I cant be up till Friday evening or Saturday morning. Ill know for sure later in the week. Tryng to get there with traffic on friday afternoon will suck. Thats why I am leaning towards Saturday morning. Im hoping if I leave around 5:30 am hopefully I can be there say around 8:30 to 9 am.

I should arrive Saturday morningish.

If the stars and planets align this week I may stop by.

Will this help us any?:)

http://www.advancedtubular.com/freesoft.htm

Will this help us any?:)

http://www.advancedtubular.com/freesoft.htm

The overbend calculator is great in theory, but you have to waste some tube making test bends. And once you start making a few bends on the project, its not that hard to guesstimate out in your head.

and if you under bend the tube, you can stick the tube back in and bend it just bit more, getting it perfect.


Get one of these (http://www.amazon.com/Quint-Measuring-Systems-Inc-Angle/dp/B0002EXEY8/ref=pd_bbs_6/002-4853393-6024824?ie=UTF8&s=hi&qid=1176157399&sr=8-6) and you should be fine.

and if you under bend the tube, you can stick the tube back in and bend it just bit more, getting it perfect.
Yup

Get one of these (http://www.amazon.com/Quint-Measuring-Systems-Inc-Angle/dp/B0002EXEY8/ref=pd_bbs_6/002-4853393-6024824?ie=UTF8&s=hi&qid=1176157399&sr=8-6) and you should be fine.
I was planning to steal the 24" one from work. :)

Some other stuff you'll want/need:

1) spray lube. Get lithium based stuff, lube the dies to help stop galling. if it looks like someone sneezed all over the dies and it got messy.. then you've got the right stuff.

2) black and silver sharpies. black for the clean tube, silver for anything that isn't clean.

3) green 3m pads, rags/towels, brakecleaner, and wd40. wd40+green pads to scrub the tube, brakecleaner/towels to clean off the results. Use this to clean the tube before you bend it. You have to get all the dirt, rust, and oil off before you can bend/weld it. The cleaner the better!

4) ratchet straps, bungie cords. Use these to hold the cage together as you build - no need to tack weld until your ready. This one is truly a "more is better".

5) sidewalk chalk. Yep, this allows you make up diagrams on the concrete of what your trying to do - so you can use that calibrated eyeball to make sure your bending the right thing at the right time.

6) Fence post level. Go look at one, and you'll see why.

7) Bullet level.

8) Angle finder - prefer one with a strong magnet.

9) Several different protractors - different sizes due to tight places.

10) welding magnets - they do come in handy.

11) an angle grinder with wire wheel, and the 24/60/120 grit flap wheels. good for removing any mill scale (the brighter the metal, the easier/better the weld)

12) drum sanders/drum flap sander. I use these to re-surface the dies to remove galling marks. I normally chuck these into a die grinder..

I'd also recommend bringing you own welding helmets and gloves - welding flashburn SUCKS.

Alright...Jury Duty done!!!;)

So I guess it's just me and you Jefe on Friday. When is John coming? We should kinda figure out what all we want to get done Friday.

Also I stopped by IMS today. They have those 3x3" or 4x4" 3/16"s squares with the holes already drilled. I know we were talking about welding, but couldn't we just use some of those? I don't think we'll have any weird shapes needed for our rigs. If so I know my dad has a trash can of scrap metal we could find something in. I figured we could use the holes to weld in to for strength. Also ...they're cheap! .60 cents for the 3x3's and .90 cents for the 4x4's. Of if you want me to just grab some flat 3/16"x3". Just let me know how much we think we'll need. IMS has 10 footers.

Lets see, what I have from Tom's list.

2.Sharpies
3. 99 cents store trip;)
4. I have 3 or for rachet straps and some bungees.
5 Chalk. That being married to a teacher thing again:thumbsup:
7. I think Tom meens the one that hangs from the string :scratch: if so I have 2.
8. Have a angle finder
9. have kids plastic one...:dunno: (teacher thing again)
11. Have a wire for my hand grinder, also have one on the big bench grinder. I may have a flap disc laying around.
12. no sander...:( or I should say my dad has one but it don't work.

By the way the metal should be really clean ..no rust or anything. This place is pretty good about that.

Lets see, what I have from Tom's list.

2.Sharpies
3. 99 cents store trip;)
4. I have 3 or for rachet straps and some bungees.
5 Chalk. That being married to a teacher thing again:thumbsup:
7. I think Tom meens the one that hangs from the string :scratch: if so I have 2.


Hmm.. THIS, or AKA torpedo level. (http://www.amazon.com/Johnson-Level-5500M-Magnetic-Aluminum/dp/B0009WG44A/ref=sr_1_2/102-0129699-9424966?ie=UTF8&s=hi&qid=1176185214&sr=8-2)



8. Have a angle finder
9. have kids plastic one...:dunno: (teacher thing again)
11. Have a wire for my hand grinder, also have one on the big bench grinder. I may have a flap disc laying around.
12. no sander...:( or I should say my dad has one but it don't work.


Try THESE (http://www.amazon.com/Merit-Abrasives-37511-Wheel-Micro-mini/dp/B0002FSXJI/ref=sr_1_4/102-0129699-9424966?ie=UTF8&s=hi&qid=1176185379&sr=1-4) You can chuck them up in die grinder..

The flap disk for the grinder is to remove mill slag off the plate and tube.. if it's not shiny and bright when you go to tack, the tack will not hold.


By the way the metal should be really clean ..no rust or anything. This place is pretty good about that.

I've gotten clean metal here, you still need to remove everything down to bare metal - the tube will have some sort of coating on it to prevent rust (oil, grime, and other gunk).

I don't know if John will be stopping by. He's got something scheduled for Saturday.

Also I stopped by IMS today. . .
I don't know if I'm comfortable with 4x4. :dunno: Tom Rios' cage plates were more significant than that, more like 4"x6". Assuming that size, thats 3' of 6" flat stock per explorer.

Here's what I have for the webcam:
http://www.jefethegreat.com/webcam/
I'll set it up in my office tomorrow so you all can watch me work. :p: I want to let it run for a few hours so I can get an idea of how much drive space I need for the weekend as I'll be capturing shots locally so we can do a time lapse movie. :cool: I wanted to do 3 cameras with #3 being Stic-cam, but its already taxing the laptops P-III :rolleyes: CPU pretty good, and I didn't really want to deal with dragging a whole PC down there.

I see you. :D

Is there a way to have it constant stream rather than refresh every 20 sec.?

I see you. :D

Is there a way to have it constant stream rather than refresh every 20 sec.?
Not without a lot more bandwidth, or limiting the number of connections. I'm just not sure how many people will be tuning in. :dunno: I'm also working with the limited CPU.

Ah... what are you watching? :)

Ah... what are you watching? :)
Star Trek: Enterprise

Webcams are back up.

Webcams are back up.

I seee you. :D

10 seconds is better than 20!

I seee you. :D

10 seconds is better than 20!
I was going to see if I could manage 5 or 6 sec when I get a chance. So far the faster frame rate isn't taking much more CPU. Anybody with a slow connection have problems with the 10s refresh?

what do you do for work, looks like you have your own private office.

lol this is good. I will be tuning in every now and then to see how the work is going.

I don't know if John will be stopping by. He's got something scheduled for Saturday.


I don't know if I'm comfortable with 4x4. :dunno: Tom Rios' cage plates were more significant than that, more like 4"x6". Assuming that size, thats 3' of 6" flat stock per explorer.

Here's what I have for the webcam:
http://www.jefethegreat.com/webcam/
I'll set it up in my office tomorrow so you all can watch me work. :p: I want to let it run for a few hours so I can get an idea of how much drive space I need for the weekend as I'll be capturing shots locally so we can do a time lapse movie. :cool: I wanted to do 3 cameras with #3 being Stic-cam, but its already taxing the laptops P-III :rolleyes: CPU pretty good, and I didn't really want to deal with dragging a whole PC down there.

Jefe I can drag the "Solid Pictures" CPU down. I also have a 15" flat screen laying around I can bring.

Intel Pentium D Processor
3.0GHZ
Windows XP Pro
250GB Hard Drive
2GB RAM

The only issue would be it does not have wifi in it, so we would need to run a long cable for the internet, or something.


So for the metal, should I just grab about 20 feet or 6"x3/16" flat stock?
I can call totten and have them add it on the truck for friday.


By the what's in the cup? Dr pepper? :D ...HEY? Where did he go? GET BACK TO WORK!:p:

Jefe I can drag the "Solid Pictures" CPU down. I also have a 15" flat screen laying around I can bring.

So for the metal, should I just grab about 20 feet or 6"x3/16" flat stock?
I can call totten and have them add it on the truck for friday.

By the what's in the cup? Dr pepper? :D ...HEY? Where did he go? GET BACK TO WORK!:p:
Well fine. . .ok, just bring the 15" LCD down. I'll bring my media server. its got a big drive, wifi, a wireless keyboard, and a video capture card for your stic-cam.

20' of 6"x3/16" sounds good. I think thats what we've been trying to say all along :p:

Its Hot Chocolate. But its about time for a DP. :D And I have to talk to people and check on stuff in the shop, so just because I'm not in my seat doesn't mean I'm not working. :p:

what do you do for work, looks like you have your own private office.
I do. I'm an Audio/Video Systems Engineer/Programmer.

Well fine. . .ok, just bring the 15" LCD down. I'll bring my media server. its got a big drive, wifi, a wireless keyboard, and a video capture card for your stic-cam.

20' of 6"x3/16" sounds good. I think thats what we've been trying to say all along :p:

Its Hot Chocolate. But its about time for a DP. :D And I have to talk to people and check on stuff in the shop, so just because I'm not in my seat doesn't mean I'm not working. :p:

Cool, I give totten a call, and I'll bring the screen, and stic cam.;)

mmm Dr. Pepper... Ok I have to go down stairs to the store now:p:


Edit: I forgot..Totten dosn't have flat stock,:banghead: I'll have to get over to IMS and pick up some.

It runs fine ever six seconds for me.

It runs fine ever six seconds for me.
I just updated it a few minutes ago. however now my CPU fan runs constantly. :rolleyes:

. . .and I'll bring the screen, and stic cam.;) . . .
How long is the cable for it, and what kind of power does it need? Wondering if I should grab/make a cable so that we can move it around the yard throughout the day.

I see you drinkin the DP haha cool.

How long is the cable for it, and what kind of power does it need? Wondering if I should grab/make a cable so that we can move it around the yard throughout the day.

Stic cam or the screen?

I'm gussing you mean stic-cam... i think we're fine there;) Is 80' long enough? :p: I normally have it all coiled up in the truck. but we can make it longer if needed just with a standard phone cord.

The power just plugs in at the sorce for the RCA cords. normal 110. I usally run a small power inverter in the truck, which I just ordered a 1000 watt to be hard wired into the truck. Then I can use the power tools anywhere:D



EDIT:also Jefe, is there anyway you but a chat feature on under the web cam, or is that to much work? I know that had that when they did colins engine swap.

I'm gussing you mean stic-cam... i think we're fine there;) Is 80' long enough?
LOL, yeah that'll probably be fine.

Bwaaaaah!!! I had Jack in the Box for lunch too!:D

Sourdough Jack
Currly Fries
D. Pepper...Although I was seriously thinking of a Strawberry Soda.

Bwaaaaah!!! I had Jack in the Box for lunch too!:D
Mine was a Sourdough breakfast sandwich, Jalepeno Poppers, and a DP obviously

webcam

http://www.sporttrac4x4.com/svocam/inthegarage.html

Harbor Freight is having a sale right now and I picked up some supplies. I also got an extra 4-1/2" angle grinder for $20.00 with tax. If anyone wants it, let me know, otherwise I am going to retun it on Thursday.

Here's what I have for the webcam:
http://www.jefethegreat.com/webcam/
I'll set it up in my office tomorrow so you all can watch me work. :p: .

Boooorrrrrrrrrrrriiiiiiiiiiiiiiiiiiiinnnnnnnnnnnnnnnnnggggggggggggggggggggggg:p:

You are drinking that soda way to slow. All the ice must of melted by now.

You are drinking that soda way to slow. All the ice must of melted by now.
Yup . . . you're right. :o

webcam

http://www.sporttrac4x4.com/svocam/inthegarage.html
I'll take still frames over that horribly compressed video any day.

Hey Jefe...what tube did you use for your front bumper? Just in case I wanted to order a piece for us to goof around with on Friday:D ...if you don't mind. I have a design in mind.;)

Hey Jefe...what tube did you use for your front bumper? Just in case I wanted to order a piece for us to goof around with on Friday:D ...if you don't mind. I have a design in mind.;)
Three sizes: 1.75" (main tube), 1.5" (radiator hoop) and 1.25" (light surround) all in 11gage.

EDIT: whats with the webcam link in your sig already? You think I enjoy random people staring at me all day??

Three sizes: 1.75" (main tube), 1.5" (radiator hoop) and 1.25" (light surround) all in 11gage.

EDIT: whats with the webcam link in your sig already? You think I enjoy random people staring at me all day??

LOL! Sorry, I'll take it down :p:

I was thinking something like this... Maybe just all 1.75 then...Just a center hoop then pieces to wrap around into the sides, but follow a little more of the contor of the lights.

http://4wheeloffroad.com/2005ultimateadventure/131_0511_adv_23_z_+1975_chevy_k10+_rock_crawling.jpg

I was thinking something like this... Maybe just all 1.75 then...Just a center hoop then pieces to wrap around into the sides.
If you're going for all one size tube, I'd say 1.5"

If you're going for all one size tube, I'd say 1.5"

So I could just order a extra stick of the 1.5 then.

So do you mind trying to fab something up Friday or would you rather just focus on the cages?

So I could just order a extra stick of the 1.5 then.

So do you mind trying to fab something up Friday or would you rather just focus on the cages?

Let's focus here people! (clap, clap, clap):p:

Nah, should'nt take too long to bend up a bumper I wouldn't think.

Let's focus here people! (clap, clap, clap):p:

Nah, should'nt take too long to bend up a bumper I wouldn't think.

It just the top...3 bars...:rolleyes:

Ahhhhhhhhh, I think we should stick to cage building....I mean I know you guys are awsome fabricators, but I think we are cutting it pretty thin as is with all the work to do. Especially since I don't know s^%t about this stuff.

Got the interior gutted, man there is a lot of room in there with no seats or rear panels. What a dirty job; 13 years of spilled sodas, fries, change, gum, trail mix, dog treats, shell casings........I found a lot of memories under that carpet.

I also found a crack running along about 2/3 of the bottom of the firewall where it meets with the floor. Some of it looks like its been there for years, some looks pretty new on the right side (the side it landed on). You can see daylight in a few places. I got to weld that back up. It looks like it was spot welded and then a sealent was put over that. Noticed all the sealant has dried up and cracked all over the body where the sheet metal panels meet up. Couple tubes of silicone and it will be good as new.

Bill, you still coming out? I got a growler (2 liter bottle) of three year old Stone Old Guardian Barley Wine in the fridge I can bring up. Its been calling to me since I put it in there last month. Can only drink it if we have a few more people though, all who are staying over cause its potent. And, it has to be consumed in 24 hours after its opened or it goes flat.:chug: :bdrunk:

The bender now sits at a comfortable working height. :thumbsup: It could still use some more work (a fourth leg and some leveling feet), but I'll have to wait for some scrap tube to finish it.

So do you mind trying to fab something up Friday or would you rather just focus on the cages?
The cage is the first priority. If we manage to get to a stopping point on our two cages on Friday, then I have no problem going onto something else at the end of the day. My goal for friday is to get our B and C pillars bent and at least a good start on the A pillar. That way we're ready for the other rigs as they arrive Saturday.

The cage is the first priority. If we manage to get to a stopping point on our two cages on Friday, then I have no problem going onto something else at the end of the day. My goal for friday is to get our B and C pillars bent and at least a good start on the A pillar. That way we're ready for the other rigs as they arrive Saturday.

Sounds Good! :thumbsup: I just wasn't sure what you want to try to get done Friday...now I know. That should get us in good shape for Saturday.

Brian, Bill said he would not make it up till sunday maybe. He has his Tiki Farm thing on Saturday

Work goes by so much faster at 128x speed. :D
http://www.jefethegreat.com/webcam/Work_x128.wmv

Haha, that's good. Should edit some kind of busy bee type of music in there.

I saw dual DPs in there at one point. :D

My co-worker gil said he would stop by and help sat and sun. He's the the one that had the Nissan Frontier at T-haven...although it's starting to look a bit different now. He has Titan arms and King coil overs on it now. :D

My co-worker gil said he would stop by and help sat and sun. He's the the one that had the Nissan Frontier at T-haven...although it's starting to look a bit different now. He has Titan arms and King coil overs on it now. :D

I remember him saying that he was going to do that. I'd like to see it.

Sarah and my Dad are both coming up to help out. We are all set for gophers and tube mules.:p:

Just came back up from downstairs gutting the truck. Your right Jefe...took longer to find a place to put everything then it did to get the seats out. I had equip. stashed everywhere. What really makes it a pain is when you can only open the doors about 30*.:rolleyes: Truck is too tall and the doors at the top hit supports for the garage.:( Unlike Brian, I only found a screwdriver under the carpet...(I wondered where that went) Under the carpet was pretty clean, it's just the cargo area that I need to clean out the coating of truckhaven dust.

Ok so here is who I have coming and when...

Friday...

Jeff
Steve
Brian+ Fam(arives in the evening)

Sataurday...

Colin
Matt
Tom
Dave
Gil

Sunday
Bill

Hopefully John can make it down for a day.

Miss anyone?

Unlike Brian, I only found a screwdriver under the carpet...
You're lucky then. I found a dollar worth of change, a random assortment of chips and crackers, some GameBoy games, lots of dust, and about 60oz worth of dried soda. :o

I found compressed air to be the best way to clean out the floor. I was debating taking a garden hose to it at one point, but I think that would just wash all the crap into the wiring harnesses.



I think I have more stuff in my truck than I've ever carried before. :eek: I just kept pilling it in until I couldn't find anything else that looked useful in the garage. :rolleyes: Luckily for John, the Mini wouldn't quite fit in the back of the Explorer. :D

My list:
Bender, 3 dies & misc parts
Tube notcher & hole saws
MIG Welder, tank and cart
welding blanket
4.5" Angle grinder
corded and cordless drills and bits
dremel and bits
all my normal tool boxes
air hose
die grinder
extension cords
computer and laptop
Tent
Fire extinguishers
And a bunch of my scrap metal

One more trip to Lowes for some hardware and I think I'm ready to go.

I stopped this morning and picked up the flat stock. I only got 4" wide. hope that alright..:rolleyes: That the widest they had ready to go, other wise I'd have to wait for them to cut it and stuff...and I had to be at work.

So I got 2) 10ft 4"x3/16". for almost $60 bucks:eek: :thumbdwn: nobody said IMS was that cheap.:rolleyes:



Jefe what time you coming over in the morning?

I only got 4" wide. hope that alright..:rolleyes:
We'll just have to cut it to 6" lengths then. :p:

Jefe what time you coming over in the morning?
8:00 or 9:00? Fighting traffic the whole way. :rolleyes:

Don't forget the colored electrical tape to label your tools! :)

Don't forget the colored electrical tape to label your tools! :)
Thats what Sharpies are for. :)

We'll just have to cut it to 6" lengths then. :p:


8:00 or 9:00? Fighting traffic the whole way. :rolleyes:

This may sound crazy, but you may wanna come down the 5 to 134 to 210. The 210 through La Canada is a bear going east! Everyone is cutting down to the 2 to get to downtown.


Oh hey jefe..I found these conectors under my seats with yellow caps on them, are those for power seats :D

Do you guys want me to bring anything besides my great personality?

Everyone is cutting down to the 2 to get to downtown.

Oh hey jefe..I found these conectors under my seats with yellow caps on them, are those for power seats :D
Yeah, I do the same thing. Sometimes I even go to the 110 to head downtown. All depends on the 5 traffic though, as I have XM traffic on my Nav unit in the Focus. :cool:

And the Yellow caps are for side airbags, not power seats. Why they run wires for airbags in every model regardless of equpment, yet only run power to seats if they are equipped with power seats is beyond me. :crazy: I had to run a wire from my driver seat over to the passenger seat when I upgraded seats. :rolleyes:

Do you guys want me to bring anything besides my great personality?
Bring us food. :D
I still haven't even thought out what to do about food. Its not like I'm going to be running out to grab something with my one seat and half a cage installed. :eek: I do however have a 12 pack of DP packed. LOL

Got it.

I do however have a 12 pack of DP packed. LOL

That will not last very long:rolleyes: I thought about going over to Costco and getting a case:D

I'll bring my little fridge, so we can load it up and keep stuff out ware we are working cold.;)


By the way there is a great burger place up the street, and we'll have the Thunderbird to run for things if needed.

..and your right...it loud in there with no carpet! There is a hole where I ran the t-case lincage and it's like my head is under the truck!

Last night when the wind came up I went and checked the weather, and it said it would calm down by today. Now the weather says it'll be windy all weekend. :rolleyes:

Do you guys want me to bring anything besides my great personality?
Safety glasses:p:

I was hoping it would be cooler this weekend because its nice to work in cool weather.

I have 2 4.5" grinders. 4 or 5 welding magnets. A couple of torpedo levels. A mini right angle air die grinder with 2" pads for it. A welding blanket. Probably are a few more things that I am missing as well.

Steve what plug do you have on your plasma cutter/ 220v welder? I have a 30' extention cord with the 3 prong plug that standard welders come with. I can bring that if needed.

Do we need any extention cords? I have 150' of 12 guage extention cords that I can bring as well.

I have a case of Dr Pepper that will be traveling with me. :D

Tracy and I will try to get up there as early as we can on Saturday.

We have lots of ext cords the more the better though. As far as the welder it's just that normal 3 prong 220 plug I think. The motor home plugs into the same I think too. We have 2 220 outlets, but the air compresser runs off one. My dad got is wire hooked up to gas, it giving him trouble though. He is over trying to get it worked out right now. Something about the argon tank not letting out a high enough presure.

I think we'll be ok with wind. It normally dosn't get to bad there, and were pretty well sheltered. At least were not at T-haven now.:(

Do we need any extention cords? I have 150' of 12 guage extention cords that I can bring as well.
I've got two 25' 12 gauge cords packed. I'm sure we'll post up tomorrow if we're needing anything else, once we get the tools and rigs laid out.

All I can say is I hope there are a multiple 20A circuits available, because otherwise we'll be blowing breakers with the collection of power tools we'll have on hand. :D

Does anyone have a portable band saw? Once we get 4+ bends in these hoops trying to use a chop saw to cut them to length will be a pain.

I've got two 25' 12 gauge cords packed. I'm sure we'll post up tomorrow if we're needing anything else, once we get the tools and rigs laid out.

All I can say is I hope there are a multiple 20A circuits available, because otherwise we'll be blowing breakers with the collection of power tools we'll have on hand. :D

Does anyone have a portable band saw? Once we get 4+ bends in these hoops trying to use a chop saw to cut them to length will be a pain.

I have a 6000w miller arc welder/generator I can bring if you want. It should run all weekend on 5 gallons. Only problem is the sucker is heavy so if I bring it then I need to tow. Its already loaded in my chevy and its to heavy for me to move around.

Tracy and I are masters with cutoff wheels on grinders. We can use them to cut the stuff that wont fit the chop saw.

Bring us food. :D
I still haven't even thought out what to do about food. Its not like I'm going to be running out to grab something with my one seat and half a cage installed. :eek: I do however have a 12 pack of DP packed. LOL

I'm bringing some potato salad, and willing to do what ever errands need done. I'm leaving Carlsbad about 8:00am, have no idea how long it will take me. Luckily it's saturday and shouldn't be too bad.

Hey Bill if you want a ride give me a holler. :D

I have 2 4.5" grinders with six sanding disks (40 and 120 grit). 4 welding magnets. A mini right angle air die grinder with two and four inch pads. All of my air tools, Two Drills, assorted bits (large and small), A metal hole saw kit with lots of bits, My tool box, my air compresser, a few extension cords, a work light, my 110 flux core welder, my dremel set for tight spots, safety glasses and a few pairs of leather gloves, probably are a few more things that I am missing as well.

I also brought my front door panels and the kick panels, removed of course, if my Explorer interior is different than the 2nd gens.

And I have Colin's right side door!:thumbsup: :thumbsup: :thumbsup: :thumbsup: :thumbsup:

And............my EMT bag, just in case:rolleyes:

Oh yeah, my door...think that will fit in the audi wagon?

Oh yeah, my door...think that will fit in the audi wagon?
We can make it fit!:eek: :eek:
I can't park the Camry in the garage right now because its full of Explorer parts, I never thought there was so much crap in that thing.

Anybody else noticed any cracks in the firewall where it meets the floor pan, or am I the only one?

Anybody else noticed any cracks in the firewall where it meets the floor pan, or am I the only one?

Josh S. had the same crack(s) when we gutted his. :confused:

Does anyone have a portable band saw? Once we get 4+ bends in these hoops trying to use a chop saw to cut them to length will be a pain.

no band saw but my dad as that cool metal skil saw thing...it cuts like butter!:D

Yeah, use metal cutoff blades in skilsaws. :thumbsup:

Tom, if I go, it won't be till Sunday.

Is Sunday going to be a 'work' day, or will things be wrapped up by then, like a T-haven run? ;)

I have a good feeling there will be plenty still going on for sunday. We will know more Saturday evening though.

I went and picked up some stuff off Tom's list. and I got this bad ass torpedo level.:cool:

All set up with a magnet for pipe, and the angle finder biult in.:thumbsup:

http://www.stanleytools.com/catalog_images/mid_res/43-609_mid_res.jpg
http://www.stanleytools.com/catalog_images/Opt_Img2/mid_res/43-609_mid_res.jpg

Jefe ...Bring a monitor cord, I only have one..and it pluged into the one I'm using now. (not the power cord)

I do have a monitor extintion cord if needed...:confused:

Jefe ...Bring a monitor cord, I only have one..
Uh, ok, will do. That would have been nice to know while I was at work and had 2 on a shelf within arms reach. :p:

I still haven't made it to Lowes/Home Depot, so I gotta stop there on the way in the morning. :rolleyes:

Yeah, use metal cutoff blades in skilsaws. :thumbsup:

Tom, if I go, it won't be till Sunday.

Is Sunday going to be a 'work' day, or will things be wrapped up by then, like a T-haven run? ;)

Sorry Bill. It would be great if you could make it sat. I have visitors on sunday.

Brian, great you're taking the EMT kit. With so many power tools around it's going to look like something out of tool time:hammer: :frustrate :confused:

Uh, ok, will do. That would have been nice to know while I was at work and had 2 on a shelf within arms reach. :p:

I still haven't made it to Lowes/Home Depot, so I gotta stop there on the way in the morning. :rolleyes:

sorry, I almost forgot to pack in the truck, and when I dug it out, remembered. I can always stop by Comp USA. Everthing is on sale there anyway now.

Well, I'm just now loading the computer into the truck. But hopefully its just a matter of connecting some wires to get it running in the morning. Hopefully. :rolleyes:

Well, its the end of day one, and I am tired. Sitting in the RV in Norm's driveway. Jefe is real good at this tube bending stuff, and I sure am glad he is here.

Well, its the end of day one, and I am tired. Sitting in the RV in Norm's driveway. Jefe is real good at this tube bending stuff, and I sure am glad he is here.


No EMT kit use?

No EMT kit use?

Nope, no major organ or blood loss on this run. It wasn't really a cage building party, more like a cage tube bending party. I now have a fully disassembled roll cage in my disassembled Explorer in the garage. We realized we were going to run out of time and decided to just bend all the tubing.

I now have a fully disassembled roll cage in my disassembled Explorer in the garage.

:D That is funny. lol You guy's must be worn out. I was there for a while on saturday as a gopher and it wore me out. Notching tubing isn't a easy as it sounds. It took us 1 1/2 hrs. just to do the drivers side. sheesh. So what's next?

I think My plan is next weekend, go back to making sure everything is fitted right. need more grinding on stuff. Also play with innterior piece to make them work with the cage. Then I'lll get my new upper tube for my front bumper welded on ( thanks Jefe,John and Matt for sticking around to do it:thumbsup:)

Then the following weekend All start painting most of the cage (Apple Red) and then start welding it in.;)

:ttiwwp:

:ttiwwp:
Try our chitchat thread:
http://www.explorerforum.com/forums/showthread.php?t=184530

Try our chitchat thread:
http://www.explorerforum.com/forums/showthread.php?t=184530


Thanks Jeff.

I thought this link may help some of us from this weekend. It how to notch with out a notcher, and there is a neat program to figure everything out tords the bottom of the 1st page of the thread. ;)

http://pirate4x4.com/forum/showthread.php?t=456800

I think My plan is next weekend, go back to making sure everything is fitted right. need more grinding on stuff. Also play with innterior piece to make them work with the cage. Then I'lll get my new upper tube for my front bumper welded on ( thanks Jefe,John and Matt for sticking around to do it:thumbsup:)

Then the following weekend All start painting most of the cage (Apple Red) and then start welding it in.;)
Ditto, exept I don't really have a plan. I am just going to work on it when I have time, and I think I am going to paint the cage a nice mellow brown (won't show dirt so much, and will sort of match the interior).

I thought this link may help some of us from this weekend. It how to notch with out a notcher, and there is a neat program to figure everything out tords the bottom of the 1st page of the thread. ;)

http://pirate4x4.com/forum/showthread.php?t=456800

Save empty paper towel rolls is priceless.:thumbsup: