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I'm thinking about making a Rollcage for my 94 Bronco. What size pipe are they made from? Does anyone know of an aftermaket source for these. It would be nice to have something to copy off of.
Look at [link:www.rlms.com|Red Line Motorsports]. They have all kinds of pictures & specs. They even have an order form that shows you how to measure your vehicle for a cage. If I could figure out how to bend the pipe, I'd make one for my truck.
Considering how much a 78-96 Bronco might weigh and if you roll it you get squished flat, here is what I would recommend.
2" x .120 DOM tube with a double halo type hoop somewhere near the rear passenger area so the people in the rear seats do not get crushed. Having a double hoop rear and middle is even better.
Having cut apart my 1986 Bronco I can tell you the solid feel of the roof is an illusion. It feels solid from the foam Ford squirted in there between the inner and out shell of the roof. Your doors probably provide more roll over protection than the roof.
As for one of the previous links showing seamed pipe being used, you can expect that to split vs. deform (for DOM tubing) when subject to the stress of a severe roll over.