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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 Yost Offroad Staff Member Moderator Elite Explorer

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    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
     
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  3. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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  4. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    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 Yost Offroad Staff Member Moderator Elite Explorer

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    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 Yost Offroad Staff Member Moderator Elite Explorer

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  7. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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  8. Spudhut

    Spudhut US Navy Submariner Elite Explorer

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  9. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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  10. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    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 Yost Offroad Staff Member Moderator Elite Explorer

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    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

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  13. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    You are welcome. Here is more I did today.
    20180514_113257.jpg 20180514_113306.jpg 20180514_131024.jpg
     
  14. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    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 EF Vendor

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    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 Yost Offroad Staff Member Moderator Elite Explorer

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    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 EF Vendor

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    I think it looks good. Definitely well thought out and not just slapped together.
     
  18. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    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

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    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!
     
    • Like Like x 1
  20. gmanpaint

    gmanpaint It's Always Something! Staff Member Moderator Elite Explorer

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    Dang, that's pretty slick.

    Nice thinking outside of the box.....(pun intended).




    P.S. I'm jealous of all them fab tools!
     
  21. yostyexplorer94

    yostyexplorer94 Yost Offroad Staff Member Moderator Elite Explorer

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    Haha
    I wish I had more time to use the fab tools!
    I still haven't finished the A pillar or tied the cage to the frame.
     

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