Dismiss Notice



Register Today It's free! This box will disappear once registered!

Yostyexplorer94's Hybrid Roll Cage

Discussion in 'Offroad Fabrication - Bumpers, Sliders, Cages etc.' started by yostyexplorer94, April 15, 2018.

  • Searches ExplorerForum.com
    1. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      I have been working on fabbing a hybrid style roll cage. The current "plan" is a halo around the entire roof and the A pillar tied externally into the rock sliders. B and C pillar will be internal tied into the halo through the roof. I am still up in the air on how I want to attach the D pillar.

      I made cheater bars to get my measurements for the main B pillar hoop.
      20180319_014840.jpg

      The first thing I am bending for my cage and I find a bend that my vertical bender cannot do without getting creative. If I had bending software I could have bent the tube in ways to avoid having to do this, but this way worked and it was a way I understood without risk of wasting tube!
      My vertical bender being used horizontally!
      20180319_033721.jpg

      Close enough.

      20180323_013936.jpg
       
    2. Support EF

      Join the Elite Explorers for $20

      Explorer Forum has probably saved you that much already, and will continue to save you money as you learn how to diagnose fix problems yourself, and learn which modifications work without having to experiment on your own. Elite Explorer members see practically no ads, can add their own profile photo, upload photo attachments in all forums, and Media Gallery, create more private Conversations, and more. Join Today. Your support is greatly appreciated.


      to hide adverts.
    3. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
    4. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      I determined that the cross members of the halo had to be bent because this is way too high off the roof for my taste.

      20180408_174949.jpg

      20180408_175003.jpg

      I bent the cross members to 22.5°

      20180410_015753.jpg

      20180410_015814.jpg
       
    5. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      Much better. I wish I could have got it tighter to the body, but the way the explorer doors are at the top, this is all the closer I can get it. I am not completely sold on the looks at the windshield though.
      20180410_163136.jpg

      20180410_163144.jpg

      20180410_163157.jpg

      20180410_163202.jpg

      Triangulation time.

      20180411_021748.jpg

      20180411_021800.jpg
       
    6. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
    7. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
    8. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      366
      Media:
      72
      Albums:
      2
      Likes Received:
      79
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      Nice work
       
    9. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
    10. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      ¼" plate welded to the floor, bolted to the lower seat belt attachment point, and welded to the B pillar.
      20180507_130508.jpg

      B pillar hoop welded in

      20180507_142805.jpg

      20180507_163930.jpg

      I tied the hoop into the upper seat belt attachment point. 20180507_183954.jpg
      20180508_102922.jpg 20180508_103033.jpg
       
      Last edited: May 8, 2018
    11. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      ¼" plating over top of the body mounts 20180509_121035.jpg

      ⅜“ bar stock with the body mount bolts securing it
      20180509_121046.jpg

      C pillar hoop

      20180511_120201.jpg

      Tied the cage to the upper seat belt mounts

      20180511_120215.jpg
       
    12. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      366
      Media:
      72
      Albums:
      2
      Likes Received:
      79
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      Fine work, thanks for the updates...
       
    13. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      You are welcome. Here is more I did today.
      20180514_113257.jpg 20180514_113306.jpg 20180514_131024.jpg
       
    14. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      Finished minus the a-pillar bars.
      20180522_131038.jpg
      20180522_131118.jpg
       
      Last edited: June 14, 2018
      • Like Like x 1
    15. Mbrooks420

      Mbrooks420 High Voltage. Elite Explorer

      Joined:
      February 2, 2002
      Messages:
      6,695
      Media:
      3
      Albums:
      1
      Likes Received:
      282
      Trophy Points:
      103
      City, State:
      Erie, Pennsylvania
      Year, Model & Trim Level:
      1998 Mountaineer AWD
      What don’t you like about the windshield? The clearance? I’d jam an LED light bar in there if you wanted it to look tighter.
       
    16. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      More so the contour of the cage to the windshield. I kind of like how it looks now.
       
    17. Mbrooks420

      Mbrooks420 High Voltage. Elite Explorer

      Joined:
      February 2, 2002
      Messages:
      6,695
      Media:
      3
      Albums:
      1
      Likes Received:
      282
      Trophy Points:
      103
      City, State:
      Erie, Pennsylvania
      Year, Model & Trim Level:
      1998 Mountaineer AWD
      I think it looks good. Definitely well thought out and not just slapped together.
       
    18. yostyexplorer94

      yostyexplorer94 1st Gen Mod Staff Member Moderator Elite Explorer

      Joined:
      September 6, 2006
      Messages:
      590
      Media:
      2
      Likes Received:
      64
      Trophy Points:
      38
      City, State:
      Newburg, PA
      Year, Model & Trim Level:
      1994 Explorer
      Callsign:
      yosty
      Thank you! I stared at everything for days just to get a plan on how to build it. There were many hours of scrolling through build threads, fighting with photobucket photos, instagram searching, etc. to get ideas.
      I also basically learned how to bend, fishmouth with a chop saw/angle grinder, bend inside a parameter, and weld in all kinds of uncomfortable positions during this project.
       
    19. Spudhut

      Spudhut US Navy Submariner Elite Explorer

      Joined:
      August 14, 2017
      Messages:
      366
      Media:
      72
      Albums:
      2
      Likes Received:
      79
      Trophy Points:
      28
      Location:
      NW Arkansas
      City, State:
      Bentonville, AR
      Year, Model & Trim Level:
      1997 Explorer Sport - 4x4
      Callsign:
      KG5SPB
      I certainly know what you mean. Sometimes I think I spend more time looking for ideas and "confirmation" to what I'm doing each time I take on a large project or task. As for me...I just need to just dive in and make it happen. I forget its just metal and can be fixed or replaced if needed.

      That perfect look from bends to welds, to actual functionality in our creations within fabrication can be mind boggling.

      You definitely hit the mark with your cage. Great work!
       

    Share This Page







    We Support Our Troops!