Project "Cage" - JeepForum.com

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post #1 of 187 Old 08-14-2007, 08:07 PM Thread Starter
Fatman
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Project "Cage"

Ok, so the tub posts (on my part) are going to take a vacation.
We have to fit up a few things before the tub comes back off.

Ordered a Kentrol Inc. Sport Cage. The kit came with L & R floor plates, the front sport bar 0.125, and a pair of pre-bent "kicker" tubes also 0.125. As well as some instructions.

So we put the bar in moved it around and decided on 3/4" off the windshield

Oh, we put the windshield frame in place and cleaned up the old brackets, I have new black stainless everything waiting for the after paint party. Also installed the stock "show" bar


Added some oak plank to keep the gap equal, checked the angle on both sides and marked the floor.


Placed the plates and found the pre formed plate angles needed about 7* more, so some massaging with the press and we have a nice fit


Cleaned up the plates, and measured up the bar for the needed cuts, leveled, measured, repeat, repeat, repeat, ..... cut!


BTW, I'll just show one side as the left and right work is almost the same thing. Just remember to line up the tube based on the body location, not the plate location.
Left:


Right:

Fooled ya!

Next we measured out the tube for the dash bar. Super Friend let me borrow this awesome tool:



Dash bar held in by compression, need to put in old dash and cut the dash pad to check height



More pics and details to follow shortly

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post #2 of 187 Old 08-14-2007, 09:14 PM
1979CJ7
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looki good man. cant wait to tsee the rest... where did you buddy get that notcher from>
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post #3 of 187 Old 08-15-2007, 06:51 AM Thread Starter
Fatman
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To bring this up to date,
After putting on the old dash panel, we cut the dash pad with a sawsall and used a belt sander to shape the sides of the pad:


put some JB Weld on the drivers end where it became a little frayed:


I'm looking for a product that I can paint on or dip the pad in to get a nice simi-hard finish over the foam again.

Pad installed and dash bar height adjusted



Put the seats in so we could check the fit of the diagonal lateral bar


Me and my son. First time we have sat in the Jeep since November


We bent two bars out of 2" 0.225 to match the ones that came with the kit. We'll install those shortly along with the lateral and a few grab bars.
Of course the lateral goes behind the seat but you get the idea.


Random shots:



Will stop this afternoon and pick up the 3/16" for the front and center frame tie in's. Need to order some isolators for the rear tie ins and cut out the rear quarter panel supports
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post #4 of 187 Old 08-15-2007, 08:01 AM
JoonHoss
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Quote:
Originally Posted by Fatman
Quote:
Originally Posted by Fatman
this has been a very rewarding project...

Quote:
Originally Posted by Fatmans Son
this jeep will get me SOOOO many chicks...




for your dash pad- you might try contacting a place like this:

http://www.creativecolorsintl.com/

hth

Keep up the good work!

Hoss

"Genius may have its limitations, but stupidity is not thus handicapped."
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post #5 of 187 Old 08-16-2007, 06:02 AM Thread Starter
Fatman
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Quote:
Originally Posted by 1979CJ7
looki good man. cant wait to tsee the rest... where did you buddy get that notcher from>
It's a Northern Industries product, I guess that means Northern tool?
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post #6 of 187 Old 08-16-2007, 06:43 AM
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quick search yielded...

http://www.amazon.com/Northern-Indus.../dp/B0000AX6PN

cb


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post #7 of 187 Old 08-16-2007, 03:44 PM
BESRK
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Might try brushing or spraying on several coats of Plasti-Dip on those exposed ends. I've dipped rope ends into the stuff and built it up to a pretty thick coating to keep the rope from unravelling.

'80 CJ5 w/AMC360, T176, D44 w/Detroit 4.56, RE 4" YJ lift and 35s..


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post #8 of 187 Old 08-16-2007, 03:48 PM
bulljeeper
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i really the jeep so far. the rollbar is a nice touch. i just hope it doesnt have to come in handy.


oh yeah, i hate all of you who have shops, garages, and even carports!

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post #9 of 187 Old 08-17-2007, 05:06 AM
84MSRB
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Pretty cool looking stuff so far. We are definitely not doing things in the same order though.

Does that upper radius on the front bar bother you at all? I never really saw one from the angle you showed, and it looks like it takes out a decent chunk of your windshield- not that the upper corners will let you see much other than incoming aircraft, I guess.

1984 CJ7 Mud Slingin Rust Bucket
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post #10 of 187 Old 08-17-2007, 07:34 AM Thread Starter
Fatman
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Quote:
Originally Posted by 84MSRB
Does that upper radius on the front bar bother you at all? I never really saw one from the angle you showed, and it looks like it takes out a decent chunk of your windshield- not that the upper corners will let you see much other than incoming aircraft, I guess.
It's not so bad, lil bit-o trade off
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post #11 of 187 Old 08-18-2007, 06:32 AM
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Good Stuff... I need to do the same on my CJ5. Might entice my wife to ride in it. How bad was the shipping on that front roll bar?
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post #12 of 187 Old 08-19-2007, 01:00 PM Thread Starter
Fatman
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Well I was not able to pick up any steel Friday so I just did some small tasks to get ready for the frame tie-ins.

Cut up the last of my 3/16 plate.
Drivers front plate:


Drivers center, drilled out and ground off the old tie in nuts:


Plate is not enough, frame is going to hang up on the tub lip. Made isolators:


One plate was not enough to get out from the lip, used the right side plate I cut and looks like we're there.



Went back and put isolators under the front tie-ins:



Patterns are cut for the frame tie ins, will cut & install in the next few days.
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post #13 of 187 Old 08-19-2007, 06:14 PM
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looking good, cant wait to see the end of this one too,



also why did you prime over your jeep sticker?
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post #14 of 187 Old 08-25-2007, 08:33 AM Thread Starter
Fatman
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Lil teaser !
Plan on getting all the tube tacked today.
Cut all of my frame tie in plate from 1/4"
Going to do a link type setup for the rear tie in





more to come.
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post #15 of 187 Old 08-25-2007, 08:41 AM
jatepper
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Looks good fatman. Looks like you two are having a good time with the rebuild. It seems like you guys have everything you need to do the job right.

Do you guys have any room for a foster adult to come and stay for a while?

1986 CJ7 Laredo - Auto 14k miles
1985 CJ7 Renegade - Auto 33k miles
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