Here is the write up on changing the CJ rollbar to the YJ rollbar.
(Now just remember this is really no safer than the current rollbar and is not a cage and doesn’t have any supports tied into the frame.)
I originally decided to change the bar to be able to add two functions to my CJ. Number one was to have a 3-point seatbelt in the rear. Makes it easier for the car seat. The second was to give myself something to pull myself in the drivers seat verse the steering well. IMO this works well.
Now this is based on two different Jeeps, one past and current, both 80’s, but some pics were better from the first round so they are included. I might have missed something, but feel free to ask questions or add stuff to it.
Best place to get one -
Best place to find one is a junkyard or someone parting out a 92 to 95 Wrangler YJ with a family style rollbar. Make sure you get the seatbelts and the short female belts for the rear. If not you can find them afterwards locally or Ebay, etc.
The rollbar bolt holes are the same pattern for 82 to 86 CJ7 and some other years, not sure on the 76 to 82, been while since I have seen one.
Tools – Your basic tools you have, wrenches, drill, etc.
I got all my nuts and bolts at ACE Hardware and they have all the nutserts, nutsert tool and drill bits.
I got rid of all the torx, except the ones on the 3-point belts.
I replaced them all with grade 8 3/8 or 7/16 bolts, nuts, lock washers and washers for the rollbar.
4 5/16 (1/4” will work) nutserts. I think they are 18 thread for the 5/16, just get the right bolts. Make sure you see what size drill bit you need for the nutsert; it should show on the case.
1 nutsert tool 5/16
4 5/16 by 1 ¼ 18 thread bolts
2 3/8 1 ½ bolts 2 flat washer, 1 lock washer and nut.
1 ¼ steel drill bit
1 3/8 steel drill bit
1 ½ drill bit
1 step drill bit ¼ to ¾ (not required but I like them as they are faster. very pricey though)
I remove the rear seat and lap belts now. You have to start by removing the seat belts or 3 point on the CJ rollbar; you should have one on the floor and the other on the CJ bar. You can leave the seatbelt housing on the tub if you want to.
Next get the torx bolts out, 4 on the floor by the seat and 2 in the rear of the inner tub fender. You have to get the old torx bolts out; they are going to require a lot of PB, heat and aggravation. I am usually able to get them red hot with torches and use an impact gun with a torx bit 45 or 50 to remove. I have also resorted to grinding the heads off a couple or drilling them out.
Remove the CJ bar
Clean up the rollbar floor mounting areas. Get rid of any dirt or rust; paint it if you want, etc. Your choice.
Set in the YJ rollbar. You can remove both sliders if you want. If your windshield tilts forward, it is a plus but not essential. I have done it both ways
I bolt in the bar to the floor and put the seat belts on. I replace all the torx bolts with 6 point hex bolts and all grade 8.
Next is to mark a hole 12 inches from the tailgate and go 2” up from the floor. I drilled a ¼ hole and then went up in size to the 7/16 bolt through. You drill to the outside of the inner tub. You can paint it or coat it later.
Pull down your seatbelt from the YJ bar. (I added a washer to the outside of the seatbelt strap to give it a little play.) Put the lock washer and nut on and tighten it up.
You put the two short female lap belts in to the center of the floor (this is where your belts should have been. You can put the two bolts back into the sides where the bolts were, if not they will just act as drain holes.
The rear is done, now for the fun stuff.
I make sure my front supports are close to the windshield. You will have to remove the visors if you have them. I put the hard doors on to make sure they will clear the YJ front bar. (Not sure of soft tops???) Line it up with the holes on the YJ front support and make my marks. Take the doors off.
Drill out ¼” holes. Then go up to the size you need to get the nutsert in. DO NOT OVERDRILL THE NUTSERT HOLE, not fun to fix a screw up like that.
Gather up your nutserts, tools drill, wrenches.
I used a longer 5/16 bolt to set them in; I think it was 1 ½ long. Set the nutsert into the windshield, put the nutsert tool and tighten the bolt by hand. When you get close to tight, use wrenches to tighten the bolt into the nutsert tool, this will set the nutsert in. Remove tool and bolt, Proceed on to each side.
Place your front supports on and tighten up your bolts. I use flat washers or even lock washers as well. Adjust the front supports as needed.
Finally it is done.
Hope this clears up how to change it. I can do additional pics or measurements if needed. Install time may vary due to torx bit removal