Cage the Beast
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Lead Driver
Joined: May 2000
Posts: 9,236
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From: Senoia, GA
Cage the Beast
I am gearing up getting ready to start bending and welding up a full custom cage for my Bronco. I plan to use 2"OD with .120" wall. I am looking for designs to model after. I have looked at pirate but I wanna see more! I wanna get creative. I plan to use a rear bench seat with 5 pt safety harnesses as well as captains chairs up front with 5 pt harnesses. I am thinking it would be a good idea to exo-cage the hood area too! Any and all suggestions are more than welcome as always.
Thanx guys
-cutts-
Thanx guys
-cutts-
Posting Guru
Joined: Feb 2004
Posts: 1,066
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From: Chatsworth, CA
whats better bolting it to the frame or welding it? I'm hearing welding on the frame is bad because it can weaken the frame. I guess just use some 8 grade hardware and bolt it right? Just don't go all crazy Fish and make it a jungle gym. What do you guys think about exterior full body cages that protect the whole rig? I don't think they look very good.
Postmaster
Joined: Jul 2003
Posts: 2,976
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From: Rep. of Texas
Id bolt it and make it at least an 8 point. That way if you roll it bad itll save you but you can get it off easily to replace it if necessary. Or if you had a wreck in it with an 18 wheeler semi or something.
Post Fiend
Joined: Sep 2000
Posts: 8,238
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From: Oregon
I don't like the looks of exo-cages either, but thats just me. Welding on a frame is not inherently bad, as it can be done right. Welding on a frame the way many guys do is bad, and can weaken it and generate stress risers hastening stress fractures. Myself and many others have welded a bunch on our frames with no problems. Then again, there is nothing at all wrong with bolting it to your frame using grade 8 hardware, and can be a better choice depending on your level of welding expertise.
Junior User
Joined: Apr 2004
Posts: 51
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From: Washington
A simple cage will work just fine, there was a thread about on PBB about not going radical on cage a while back. The big thing is to have good welds and gusset the corner good, any triangluation is good too.
As for connection it to the frame, weld some tabs and use a bushing. This allows the frame and body a little flex and but the strength in the cage is kept.
Use bolt plates on both sides of the body instead of cutting a hole and running the bar straight through, this will allow for future changes (body off, new cage ect...)
With the 5 point harnesses your will have a very high cross bar behind each set of seats. 5ph should mount shoulder high, if I remember right -5 deg below shoulder to +10 deg over should, It's going to be a little hard to get to the back seat.
Another good idea would be to mound you seats to the cage, this way you will always be in the cage if the truck comes apart.
Exerior cages are UGLY in my opinion but work effective.
As for connection it to the frame, weld some tabs and use a bushing. This allows the frame and body a little flex and but the strength in the cage is kept.
Use bolt plates on both sides of the body instead of cutting a hole and running the bar straight through, this will allow for future changes (body off, new cage ect...)
With the 5 point harnesses your will have a very high cross bar behind each set of seats. 5ph should mount shoulder high, if I remember right -5 deg below shoulder to +10 deg over should, It's going to be a little hard to get to the back seat.
Another good idea would be to mound you seats to the cage, this way you will always be in the cage if the truck comes apart.
Exerior cages are UGLY in my opinion but work effective.
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Lead Driver
Joined: May 2000
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From: Senoia, GA
bob, you make a good point. i have been debating on mounting the seats to the cage or the body of the bronco but i think i am leaning towards the cage for your aforementioned reasons! also will prolly incorporate a box in the rear to retain the fuel cell! once again more protection. i don't want anything elaborate but safe and creative
-cutts-
-cutts-
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Lead Driver
Joined: May 2000
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From: Senoia, GA
Originally Posted by bremen242
honestly, I'd have someone else do it, unless you are good at MIG welding.. DONT tell me you are going to stick weld it together?
-cutts-