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Prodject "Hardcore XJ"

Geepfreak

NAXJA Forum User
Location
The Shop.....
Hope I am posting in the right place for this. But this last weekend while down in Moab, I realized I need an Exo cage, so today I started mocking up what I hope to be what saves me. I just started with what I had laying around the shop, I figured I would make the tri-agulation strong enough to save the glass and body.
Here are the main supports
3438389923232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954655ot1lsi

I missed the measurment for both sides, but I think I can make it work. I also figured that I wanted 1" conduit for the side to side supports by the windshield because of the low profile,
3438389923232%7Ffp45%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954654ot1lsi

Here is a shot from the front,
3438389923232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954664ot1lsi

I will try to make all my rolls on the Paasenger side, as it will be the side with a full door(doorless on Drivers). Tie everything into the bumpers and rock sliders. Door just clears,
3438389923232%7Ffp58%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E232384995465%3Aot1lsi

as you can see in the next pic, the front is starting to look like it's coming together.
3438389923232%7Ffp58%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954375ot1lsi


I'll get more pics up in a while, need to go work on it.
 
i'll be up next weekend we can start on mine like that :wave:
 
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So, I just went and worked on it some more, coming right along..
3438389923232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954676ot1lsi

the angles are hard to make exact but should be close, but overall the rake is hardest part to get right.
3438389923232%7Ffp58%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954374ot1lsi

Now, just trying to decide what axles to run, I have both a Dana ff60 and a Ford
9", they both have 3.73 gears, so right now it's a toss up.
3438389923232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954672ot1lsi

3438389923232%7Ffp47%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954673ot1lsi

the 35's just dont cut it, need 38's. well, last shot for today but I think the rear is going to be the hardest part of the whole build.
3438389923232%7Ffp64%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954674ot1lsi

3438389923232%7Ffp46%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E2323849954376ot1lsi


Thanks for your coments. and more to come, let the welding begin..
 
0313 said:
I like, how much would you charge to do that to mine?

Buy the materials and I can help walk you through it.
 
Geepfreak said:
Buy the materials and I can help walk you through it.

i think i can get most at true value so when you walk him through his i'd like the same.

also what you gonna use to tie it all in?
 
conduit? Why in the world would you use conduit for an exo cage? :wierd: I hope you are trying to be funny.
 
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I have gotten so excited about getting this prodject done that I had to go do some work, I know that I am not the welder that alot of you here are, but what do you think of the welds so far? would some body filler or a couple a tubes of JB weld fill in the holes ok?
3438393523232%7Ffp46%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E232384995%3B2%3C%3Aot1lsi

3438393523232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E232384995%3A%3A44ot1lsi
 
not to be rude but what the hell are you thinking?? conduit? why even bother? i was thinking of building a cage out of 1 or 2 inch square tubing that was at least 3/16 thick as a roll protection and even that i think i would get laughed at. most people use at least erw or dom tubing to build their cage and brace it pretty heavily. i wouldnt thing of using anything less that sch40 or dom if i was using round stock. and remember that the stregnth of material is what is going to be protecting your jeep if you start out with weaker materials then you will defeat your purpose. and as a last point jb weld and body fill? those are two thngs that should never be used to join a roll cage! learn to weld get a tubing bender and do it right, or use square tubing and learn to weld. that is my .02
 
i call :bs: i think it's a joke.....i hope!
 
You must have no sense of humor to really think that he is really going to be using that please. Quite a funny idea to start though with that conduit. I think my work has some 1.5" laying around. I should see what I can mock up.

renegade_z71 said:
not to be rude but what the hell are you thinking?? conduit? why even bother? i was thinking of building a cage out of 1 or 2 inch square tubing that was at least 3/16 thick as a roll protection and even that i think i would get laughed at. most people use at least erw or dom tubing to build their cage and brace it pretty heavily. i wouldnt thing of using anything less that sch40 or dom if i was using round stock. and remember that the stregnth of material is what is going to be protecting your jeep if you start out with weaker materials then you will defeat your purpose. and as a last point jb weld and body fill? those are two thngs that should never be used to join a roll cage! learn to weld get a tubing bender and do it right, or use square tubing and learn to weld. that is my .02
 
Can we move this thread to JU? I think you could fool a lot more web wheelers over there. BTW, make sure you build in a mount to put your spare tire up top, at least 12" above the roof for easy cleaning.

Also, if I could make a second suggestion, weld bolt together plates to everything, instead of welding each tube together. Bolts are stronger than welds, and you want the joints to hold up when the conduit colapses. And each part would be replaceable.
 
bbaker80 said:
Also, if I could make a second suggestion, weld bolt together plates to everything, instead of welding each tube together. Bolts are stronger than welds, and you want the joints to hold up when the conduit colapses. And each part would be replaceable.

very good point, I like the replaceable aspect of the pieces...not saying that that design when tested would not hold up extremely well...but just incase...
 
I thank you all for your replies, as for using conduit, I have a bunch of it laying around and with the right configuation I know it should work, as far as JU, I did a search over there and a couple of post gave me the idea that it can and will work. a buddy of mine called a while ago and said he had a great bumper for the prodject, a little heavy but I am going to put in some ZJ coils that should bring it right up to where it needs to be. (might need spacers to clear 38's tho).
Here is the new bumper that I am puting on.
3438396%3B23232%7Ffp4%3Enu%3D3253%3E6%3B8%3E935%3EWSNRCG%3D323293%3A86%3B7%3A%3Cnu0mrj

3438396%3B23232%7Ffp64%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E23238499668%3C4ot1lsi


Here is a shot of welding the "primary cage" to the bumper.
3438396%3B23232%7Ffp46%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E23238499668%3C6ot1lsi


I was also thinking about the guys I will be wheeling with and it worries me that with rolling on the Pass side the extracation will be pulling on the drivers side, so I think putting winching and pulling points would be a good idea. I think these should work fine as the velcro does reach all the way around the tube 1 1/2 times.
3438396%3B23232%7Ffp63%3Dot%3E2344%3D7%3A9%3D%3A26%3DXROQDF%3E23238499668%3C8ot1lsi


Thanks again for your input.
 
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