YJ Full 6 Point Cage Build & Installation - JeepForum.com
LinkBack Thread Tools
post #1 of 16 Old 12-14-2006, 09:08 AM Thread Starter
Registered User
1993 YJ Wrangler 
Join Date: Jul 2003
Location: Crawlerado
Posts: 2,406
YJ Full 6 Point Cage Build & Installation

I started my build with the obvious step of removing the factory roll bars. This was not as easy as it sounds. A couple of years ago, I herculined the inside of my jeep and I covered all the torx bolt heads and plates with that stuff. It took a long time to dig it out of the bolts and to cut it around the plates. I learned a lesson that day. Remove bolts before hercing. I also learned this stuff is tough.

Once the roll bar is out of the way, measure how wide you want your B pillar hoop to be. Remember to leave room for plates and leave a little gap around everything like the door latches and in the corner where the plates are. Take your time on this step because everything else is build around this hoop.

Thanks to Terry, I learned some new tubing tricks. Here is the first couple. It is difficult measure the legs of hoops because the top of the hoop is 7” away from the leg. The easiest thing to do is place another piece of tube to give you a spot to measure from.

When you bend hoops, it is almost impossible to be perfect. Most of the time your hoop is wider at the bottom of the legs then at the top. Use a racket strap to stuck in the width.

Once the hoop is complete, I went to work on the B pillar plates. Here was the plan: have a plate on the bottom side of the boat side rockers with a piece of 1.5” DOM tube welded to it. The 1.5” tube would go through the rocker, floor board, and top plate. Bolts (1/2”) would hold everything together.

The first step was to make the top plate (the one that sits on the floor board). It was drilled with 1/2" holes and a 1.75” hole to allow the 1.5” DOM to pass through it. The top plate was placed inside the jeep and used as a guide to drill the holes on the floor board, rocker, and bottom plate.

Floor Board

The rocker was drilled with a 1.75” hole and spacers were welded.

Finished picture of B pillar plates

E_ROCK is offline  
Sponsored Links
post #2 of 16 Old 12-14-2006, 09:09 AM Thread Starter
Registered User
1993 YJ Wrangler 
Join Date: Jul 2003
Location: Crawlerado
Posts: 2,406
B Pillar was set in and tack welded to floor plate.

After the B pillar was done, I bent a similar hoop that is perpendicular to the B pillar. This hoop followed the body of the jeep with a support on the rear fender wells. I made C pillar plates were made with supports for the hoop.

The C pillar plates will tie into the frame because the sheet metal on the fender is really weak. In order tie into the frame, I ordered some bushing from MORE. It comes with two T bushings, a piece of DOM tubing, 1/2" bolt, and sleeve. I used a couple of shock tabs to weld the bushing to the frame. Remember to make the top and bottom plate different sizes to avoid making a shear plane with the sheet metal.

A picture of the frame tie-in. These things were a major pain in the ***.

E_ROCK is offline  
post #3 of 16 Old 12-14-2006, 09:10 AM Thread Starter
Registered User
1993 YJ Wrangler 
Join Date: Jul 2003
Location: Crawlerado
Posts: 2,406
The legs where made with two bends in it. I worked my bends from the floor up to the B pillar. The first is 23 degrees to follow the windshield. The second is 67 degrees with 6 degree off axis with the first bend.

The hardest part of the A pillar legs is notching the tube at the B pillar. When I did the second leg, I took more pictures of how this was done. First place a piece of masking tape where the leg will meet up with the B pillar.

Take a small piece of tube and put a piece of steel strap vise gripped to it. The strap will help you position the tube on the curve of the hoop. Eyeball the tube with the tape and tack weld it on the B pillar.

Take your tube master and get the pattern of the notch. It is easier to push the pins with your fingers than sliding the whole pipe master into position. Transfer the pattern to the work piece (A pillar leg). You need to mark the A pillar where you think the notch will be.

A pillar legs

A pillar floor plate. Since this plates sit directly over the boat side rockers, I am not worried about it punching though the floor board, so no lower plate was made.
E_ROCK is offline  
post #4 of 16 Old 12-14-2006, 09:11 AM Thread Starter
Registered User
1993 YJ Wrangler 
Join Date: Jul 2003
Location: Crawlerado
Posts: 2,406
Windshield spreader bars

The seat mounts for the jeep didn't come out as nice as I wanted, but it will work. The first problem was actually mounting the seats to the cage. I was struggling with how to do it. My first thought was to have two hoops (directly under the seats) that attach to a piece of tube that spans the bottom of the B pillar. It didn’t work because of the bend radius of my bending die didn’t allow of a good seat attachments. So ended up putting another tube that spanned the width of the jeep right above the tranny tunnel. This also caused some problems because a straight piece placed the seat too high. At the same time, my bender could not bend a curved piece (place the tube lower and bend around the tunnel) because two of the bends were too close. I chose to have the seats a bit higher than the stock ones.

The other problem was to deal with the seat width. The seats have bolster near your shoulders. Which is nice, but the bolster stuck out right by the B pillar hoop (since I didn’t angle back). This really limited how far back the seat could travel on the sliders. I have enough legroom for me, but a person with longer legs will not like driving my jeep. The passenger seat was much easier since I can move the seat more inboard.

I put my new harness in the picture for some “bling” factor.

Work has been started on the rear hoop.

I was a little disappointed on the rear hoop. I didn’t leave enough room from rear passengers. If you seat in the back seat, you are going to hit your head on the tubing when I hit bumps on the trail. I took a lot of measurements before hand, but I guess I just didn’t get it right. I have two 80 degree bends on the hoop and I should have made the bends more like 85 degrees. I also should have made the hoop longer by a few more inches. I thought about making a new hoop for a long time and decided against it. I am running out of time and money. Also, I haven’t had a back passenger in about 2 yrs.

I almost got the roof done (do you call it a roof???).

E_ROCK is offline  
post #5 of 16 Old 12-14-2006, 09:12 AM Thread Starter
Registered User
1993 YJ Wrangler 
Join Date: Jul 2003
Location: Crawlerado
Posts: 2,406
Used a 2000lb winch in the roof trusses to hoist the cage!

FINISHED PICTURES!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

E_ROCK is offline  
post #6 of 16 Old 07-21-2008, 12:24 AM
Bubba Ray
Registered User
1984 CJ7 
Join Date: Dec 2005
Location: SC
Posts: 1,696
Very Nice!!
Bubba Ray is offline  
post #7 of 16 Old 07-31-2008, 11:01 PM
Registered User
1990 YJ Wrangler 
Join Date: Oct 2007
Location: Lancaster, PA
Posts: 341
Great job on the cage, looks awesome.

I'm gonna guess you have your stock tires on so you can fit in your garage? haha

White 90 YJ...Soft/Hardtop, 31" BFGs, 3.5" lift, Rebuilt 4.2L, Weber 34/34, Herc'd

LOOKING FOR 4cyl axles F/R, 4.10s, will trade for my 3.07s complete

Also need 16x8 rims with less backspacing
xeastend is offline  
post #8 of 16 Old 08-25-2008, 10:10 AM
Registered User
Orange_Crush's Avatar
1989 YJ Wrangler 
Join Date: Dec 2007
Location: Western Mass
Posts: 609
Heck yeah. That cage looks great. Great job!
Orange_Crush is offline  
post #9 of 16 Old 10-19-2008, 04:09 AM
Registered User
1989 YJ Wrangler 
Join Date: Feb 2008
Location: McGuire AFB (Ft. Dix), NJ/Oxford, NC
Posts: 378
VERY VERY Professional looking! Great job!


NRA Life member
Square Headlights group member #222
Armed Forces Jeeps group member #65
United States Air Force group member #12
Guns and Jeeps group member #10
Ron Paul Jeepers group member #7
yamaguy01 is offline  
post #10 of 16 Old 10-20-2008, 09:02 AM
Registered User
2001 XJ Cherokee 
Join Date: Jul 2008
Location: WI
Posts: 199
Sweet, Awsome....Nice work!

jprs_peeprs is offline  
post #11 of 16 Old 10-23-2008, 12:05 AM
JF Admin
chris87xj's Avatar
1987 XJ Cherokee 
Join Date: Sep 2006
Location: 3rd rock from sun
Posts: 14,350
really sharp there. thanks for the showing


"You can set my jeep on fire and roll it down a hill,
But I still wouldn't trade it for a Coupe DeVille."

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

To view links or images in signatures your post count must be 10 or greater. You currently have 0 posts.

chris87xj is online now  
post #12 of 16 Old 10-13-2009, 01:54 PM
Registered User
2001 WJ 
Join Date: Jul 2009
Location: Bay Area
Posts: 363
Wow, that turned out really nice! What equipment did you use for welder, notcher, bender, etc?
KDog223 is offline  
post #13 of 16 Old 06-02-2010, 07:30 PM
Registered User
1991 YJ Wrangler 
Join Date: Jul 2008
Posts: 999
nice craftsmanship
jbeebe is offline  
post #14 of 16 Old 12-15-2010, 10:12 AM
Registered User
Join Date: Oct 2010
Location: Brighton
Posts: 124
Good work... Wish I could do somethin like that!
zachk94 is offline  
post #15 of 16 Old 12-23-2010, 10:07 AM
Registered User
kurtis1971's Avatar
1993 YJ Wrangler 
Join Date: Sep 2008
Location: summerhill,pa
Posts: 365
that looks great.
kurtis1971 is offline  

Quick Reply

Register Now

In order to be able to post messages on the JeepForum.com forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Please enter a password for your user account. Note that passwords are case-sensitive.


Confirm Password:
Email Address
Please enter a valid e-mail address for yourself.

Email Address:


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page

Similar Threads
Thread Thread Starter Jeep Forums Replies Last Post
CB Radio Installation for 97-00 XJs and other vehicles XJ2000 Technical Articles & Write-Ups 2 03-25-2011 11:40 PM

Posting Rules  
You may not post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On
Trackbacks are Off
Pingbacks are On
Refbacks are On

For the best viewing experience please update your browser to Google Chrome