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Changing a CJ rollbar to a YJ family style rollbar

115K views 111 replies 54 participants last post by  Jeep4Fun77 
#1 ·
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
4 washers
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 :laugh:
 
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#48 ·
I got straight on the "nutsert" thing and got them installed. However, going by my experiences with them, I just assumed that sometime in the future they would "spin" on me. So I brazed them in with my little Mapp torch on a real fine flame. Worked GREAT! No problem.
 
#50 ·
Hi Bard - Thanks for the reply. I did use the YJ seat belt set with the center hole. I does come up just a little short. You don't need to try anything on your rig - I am just going to use a couple of those 12" aftermarket seat-belt extenders on the tub-side of the 3 point belt. That should take care of the problem.

Thanks again,
Jim
 
#54 ·
I'm in the process of doing this my self now

And have followed this post from the Begining

I had the 88 YJ roll cage that came with the 88 YJ tub

Converting this tub to fit on my CJ-7 body

I had bought the 2 side rails to the windshield off E-bay

But bought a aftermarket CJ windshield frame for the conversion

I have been looking around Richmond All week also looking for these

nutserts here I have been to Ace, Lowes and Fastenal

The only thing I have found that looks like this I have found in a Grainger Cataloge

so I ordered them and should be in tomorrow and hope these will work

had to buy a bag of 25 for $ 20.00 hope they will work they will fit a 5/16 bolt though

well guess I will have extras

But thanks for the Idea I had been Looking for an Idea to do this

the only other Idea I had was to get a 5/16 nut with the flared bottoms

( like they had on bicycle front & rear axles )

drill the holes turn the nut around and tack weld them to the windshield frame

don't think they would be as flush to the windshield frame doing it this way though

Thanks Again for the Post

tigger
 
#59 ·
Sorry, no help here. I only run a soft top. It looks to me like there would be some issues in its current form, as the sheet metal screw holes in my frame are now inaccessible in that spot. Sure it could me modified to make it all work, but it would take some grinding
 
#61 ·
Not trying to resurrect this thread, but has anyone tried this on a CJ5? If not this the family style bars, has anyone found a way to put the bar from the roll bar to the windshield on a CJ5? I am really looking for a way to ge the bar in there so the wife and I have something to grab ahold of. Thanks
 
#63 ·
Or buy a YJ set-up from a junkyard and mod it to fit. And the windshield is NOT the best anchor point. Better to go to the floor and then to the frame. At least check out what RockHard bolt-in kits do. Soon, the resurrected Poison Spyder will have bolt-in kits as well.
 
#64 · (Edited)
I'm trying to put new 3point belts in my CJ7 with the family cage. Only thing I'm not clear on is mounting of the front belt, not the spool, not the shoulder point, but the loose end.

Did you drill through the tub under the spool and mount there? All my new belts came hardware and big body washers. Like 3" diameter washers.

Bard could I get a pick of your front belts and how they mount close up?

Thanks

EDIT: Never mind, got it.
 
#65 ·
I am doing this swap right now. My family bar was removed from a 95 YJ. For some reason, the bolts on the floor of the tub on the main hoop did not line up perfectly. I am referring to the 4 bolts (2 on each side) that go directly in to the floor of the tub and not the horizontal bolts that face the rear of the Jeep which go in to the wheel well. I am going to have to modify the holes to make it fit. Not a big deal, but I always thought the YJ bars were a 100% direct swap (aside from the forward bars from the main hoop to the windshield).

I eliminated the YJ forwards bars and went with OR Fab's sport cage for the CJ. It works with the YJ family cage too.
 
#66 ·
I am doing this swap right now. My family bar was removed from a 95 YJ. For some reason, the bolts on the floor of the tub on the main hoop did not line up perfectly. I am referring to the 4 bolts (2 on each side) that go directly in to the floor of the tub and not the horizontal bolts that face the rear of the Jeep which go in to the wheel well. I am going to have to modify the holes to make it fit. Not a big deal, but I always thought the YJ bars were a 100% direct swap (aside from the forward bars from the main hoop to the windshield).

I eliminated the YJ forwards bars and went with OR Fab's sport cage for the CJ. It works with the YJ family cage too.
jatepper......could you post some pictures of the OR Fab's sport cage install. I am curious to see how that works for you.

Don't have any answer on the floor holes. Did this mod to a '79 CJ7 I used to have but had to drill all the holes for the forward mount on that rig.

Thanks.....Trap
 
#67 ·
jatepper......disregard, found your other thread.
 
#69 ·
Does anyone know what the maximum height of the roll bar can be without affecting a soft top? I plan to change out my roll cage, but I don't have a soft top yet. The YJ bars measure 1" taller than the CJ bars when they're in the Jeep. Will this be enough to affect the soft top installation?
 
#75 ·
jatepper said:
Were you able to use the existing roll cage mounting holes? I'm betting the forward bars will have to be cut or modified. If it fit "as-is" then that is great!

Looks good.:2thumbsup:
I did not have existing holes. It is a fiberglass tub. Certainly more than a bolt in but much les than a total build from scratch

Sent from my iPhone using JeepForum
 
#77 ·
Jkoz,
Great Job. I think you should do a write up on your install so other CJ5 guys can see that this can be done. Again great job and would like to hear about the install.
Completely agree :thumbsup: I have an '81 CJ5, and I would feel a lot more comfortable with my son in the back if it had one of these bars.
 
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