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Unread 02-17-2010, 01:07 PM   #1
Timo_90xj
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Hybrid cage build (exo-cage + internal)

I finally had time to start my cage build, be sure to check here often as I update the page when I get something done.

My cage will be much similar to what Erics' cage is - but it of course has things and ideas of my own. But I've looked at COJeepin's engine exo, Erics' hybrid cage and quite a few other cages on NAXJA and Pirate to figure what kind of cage I want.


I finally got my tubes yesterday, nine sticks of ~1.5" (ID) x 0.120 DOM - these tubes are in millimetre standard so not exact figures. OD is ~1.8". Bought at a very reasonable price of slightly under 6€ per meter, that's about 50-55$ for a 20ft. stick! I also bought 20pcs of weld-on 90* turns (only ~2.50$ each ), mainly to be used on bumpers and stuff like that where very tight 90* turns are needed.


This is the first time I do something like this, which means I've never used a bender before. I bought one last summer, a very high quality tool. Only downside is it's muscle- powered and cannot be used with a bottle jack. That version would've cost more than double compared to the manual version. Looks like this:




I started the build from propably the easiest part, the front hoop. And that's all I've done so far





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http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***

Last edited by Timo_90xj; 02-20-2010 at 02:28 AM..
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Unread 02-17-2010, 01:29 PM   #2
99Greenmachine
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Im subscribed...haha lets see it!
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Unread 02-18-2010, 12:32 PM   #3
Timo_90xj
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This is where I do the bending

It's freakishly cold outside - again. Around 0* right now + windchill, and similar wheather expected for the rest of the week





Got some more tubes bended and welded. A- pillars pretty much done, and the windshield crossbar





This is to show how the a-pillar tubes go up. I wanted some protection for the doors and also follow the bodyline the best I could. Dunno how well this works






I wanted to hug the crossbar as close to windshield as possible, but so that I can still remove the wiper arms if necessary - and the windshield. Barely enough room, but sufficient:




I was also going to bend the a-pillar to front hoop tubes, but I managed to somehow mess up with my measurements and the bends were not in the right place ..good thing is, I can use the tubes elsewhere so they are not useless.
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 02-18-2010, 12:35 PM   #4
austinaubinoe
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I read your sig....good call on the cage! Looks great so far, really beefy, is it your DD?
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Unread 02-18-2010, 12:41 PM   #5
Timo_90xj
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Nope, not my DD. Well it could be, but it's just too damn noisy without the carpets and no sound absorbent materials
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 02-18-2010, 02:44 PM   #6
bmyohn
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very cool Timo! Im liking it so far! Im planning on something similar this summer, possible with incorporated fender flares as well. Keep it up buddy
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Unread 02-18-2010, 07:11 PM   #7
EricsXJ
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I don't know how you manage to work out in the cold like that! I must be a wimp because I hate cold weather and it makes it really hard to work on the jeep.

Those A-pillar bars were the toughest bends to do on mine. I'm not sure how to do it other than the way you did with your railstucked in that far.

You sure you can get the wipers off?
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Unread 02-18-2010, 09:23 PM   #8
slimpartywagon
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I was wpondering.... Is it possible to tie the A Pillars together underneath the Cowl? I think that would look very clean... but I have never seen it done...
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Unread 02-19-2010, 02:02 AM   #9
Timo_90xj
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I looked at that idea yesterday. But there isn't much room because of the wiper motor, and also if you want to use the space for intake there's just no way to do that. Also welding the tube to the a-pillars would be more or less impossible because of the limited space.


Quote:
Originally Posted by EricsXJ View Post
I don't know how you manage to work out in the cold like that! I must be a wimp because I hate cold weather and it makes it really hard to work on the jeep.
Those A-pillar bars were the toughest bends to do on mine. I'm not sure how to do it other than the way you did with your railstucked in that far.
You sure you can get the wipers off?
Well, it isn't too fun but I manage. Lot's of clothes and a cup of coffee every now and then ..but I'd rather do this in summer
A-pillars sure were hard, rest should be just simple bends. I can get the wipers off, I tried
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 02-19-2010, 11:20 AM   #10
Timo_90xj
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A-pillar to front hoop tubes almost done, needs a bit more welding and a few gussets. Then it's time for front fenders, rocker tubes (door protection), and then the roof section.







This is what you get for NOT having a notcher ..suprisingly that lead to some swearing

Gotta fill that up with weld and hope it's strong enough. Or maybe I'll redo that later on.

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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***

Last edited by Timo_90xj; 02-19-2010 at 02:39 PM..
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Unread 02-19-2010, 11:39 AM   #11
Bertamus
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What are you using for tubing?? Looks like fence post
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Unread 02-19-2010, 11:53 AM   #12
Timo_90xj
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Read my first post It's just painted by the factory to protect it from rust.
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1998 Grand Cherokee 5.9 LX daily driver, 1.75" BB, 32" KM2s, HPD30 Eaton e-locker/D44a stock LSD, 4.56 gears, custom- fabbed tube bumpers and tube fenders,...

http://www.jeepforum.com/forum/f13/d...s-etc-1222317/


1990 XJ Limited (4-door), 4.0 I6, AW4, NP242, ***rolled and totalled @ 165k miles***

***Under construction***
1990 XJ (4-door), 4.0 I6, AW4, NP242, PBR 42" tires, Unimog 404 portal axles, 110" WB, full cage + uniframe completely rebuilt, front 3-link + panhard / double triangulated 4-link rear,... ***SOLD***
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Unread 02-19-2010, 12:17 PM   #13
Kettles
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You ought to beable to fill that no problem. The cage is looking good so far!
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Unread 02-19-2010, 01:10 PM   #14
Bertamus
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Quote:
Originally Posted by Timo_90xj View Post
Read my first post It's just painted by the factory to protect it from rust.
My bad... that's what I get for skimming....
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Unread 02-19-2010, 02:00 PM   #15
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Gonna build one for me next? Looks great!
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