Bent some tube this weekend...

[Jester]

Thanks to the help of a lot of you guys, I got my cage started this weekend. It started off simple, a MetalTech front profile kit, and an OEM style main hoop and legs recreated in 2” x 0.120 wall:

[Jester]

Then Cam saw I had a lot of 2” left and started making some suggestions and it turned into this:

[Jester]

Nice tight joints due to John’s tubing notcher and a lot of head scratching.

Einstein approves!

[Jester]

Many thanks go out to everybody that helped including:

Lance @ Iron Pig Offroad for hooking me up with the MetalTech front profile kit and letting me steal ideas and measurements from some of his projects!

Norm & Rob for making arrangements to purchase DOM, pick up DOM, store DOM, transport DOM...

John for not only lending me his JD2 bender, tubing notcher, welding blankets AND bringing over his Miller 210 to burn it together but ALSO for putting in a long day and late night and coming back the next day for more!

Cam for his inspiration, ideas, help, drill press, and for pushing me to get this project done!

And finally, my wife, who was very understanding as we carried tube after tube from the bender and chop saw in the garage, through her kitchen, to the 40 in the basement!


Oh yeah, it’s not done yet. Needs finish welding, Still going to make some “kickers” from the B-Piller to the halo to keep trees from getting hung on the main bar and protect my noggin. Might make some diagonal braces through the door opening too. Maybe some sort of rack to sit in the back. Hi-Lift Mount, Seat Belt Tabs…are these projects ever done?

[smtyblt]

Looks good man

[matzell]

Tim,

It looks good. I think I see GSMTR in your future!! I bought the registration and put in for time off so I will be there after a few years off.

Rob

[WES1977]

Are you plain on running a hardtop? If I put mine together with out the top on, i'm sure my Hardtop would't go on. I am in the process of putting my Profile front and OEM replacement on from metal tech.

It's taking me some time because i'm a attaching my windsheild to the cage with removable bolts, and I have to make brackets for my seat belt for topless mode.

[Jester]

Originally Posted by WES1977

Are you plain on running a hardtop? If I put mine together with out the top on, i'm sure my Hardtop would't go on. I am in the process of putting my Profile front and OEM replacement on from metal tech.

It's taking me some time because i'm a attaching my windsheild to the cage with removable bolts, and I have to make brackets for my seat belt for topless mode.

As long as you don't exceed the dimensions of the factory bar, I think you will be fine. Mine is a bit tighter than stock in the 90s because the die I used was only a 6.5" Radius, but I still have room to spare. I'm not sure what radius MetalTech uses on his OEM replacement, but I'm sure he did his homework.

I haven't put the windshield on, but I have no worries about the front bar.

Good luck with your project. Sounds interesting with the bolt-on windshield. Any reason why? Are you using a replaceable lexan or something instead of glass and the factory frame? (Which is the first thing to hit a tree on a tight off camber spot).

[WES1977]

The bolt on to my windshield is to serve less flexing of my fiberglass tube. It was bad enough were I had to adjust my rear mirror to the speed I was going. I decided not to weld to my windshield frame. I'm using the sin visors holes.

Do you have any pictures of the Tube going to the front plate on the front profile cage(at where your feet would go)?

[bkfj40]

looks good....

it will help prevent this :(

[Jester]

Originally Posted by bkfj40

looks good....

it will help prevent this :(

OUCH!

[Jester]

Okay...here is this weekend's update.

Cam came over Friday after work and helped me bend some side bars and a sweet whoop-dee-whoop bar to mount the front of the front seats to. Unfortunately, after staring at it most of the day on Saturday, I cut the whoop-dee-whoop out. Smtyblt is I'm sure about that. Sorry dude. I just couldn't make it work. There wasn't any room for my feet around the pedals.

So I made a removable front seat bar out of some heavywall (0.120?) 1" square tubing that John brought over. I welded 1/2 x 13 Grade 8 nuts into the ends of it so I can pull it out to access the tunnel and gas tank. It's tight, but I can get the tank out around the gusset.

[Jester]

Originally Posted by WES1977

Do you have any pictures of the Tube going to the front plate on the front profile cage(at where your feet would go)?

Here you go...

I used some angle I had laying around to make the foot. I had to build up the bottom with some smaller stock, staggered to work around the stamping in the floor. My slider (see next post) made a perfect spot to tie the front leg in.

The 3rd pic shows the rear of the slider tying into the 4x4x3/16 I used to repair the body.

[Jester]

The slider is my interpretation of a Butch Baker (Texican) design. It basically 2x6x3/16 tube attached to the side of the cruiser. I used some angle to locate it on the truck and cover up some rust repair at the bottom of the rocker (trimmed, of course). The pics above show some of the bracing. I've promised John he can throw a hi-lift under it when I'm done and lift the truck. I might add something back to the frame before he gets a chance. Its solid now as is, tied to the cage, 4x4, and the whole side of the truck.

[matzell]

Tim, looks good!

I am waiting for the next thread, " I started and drove my cruiser this weekend" . I am sending my registration in this week for GSMTR. After a few years off I am finally going to make it back.

Rob

[Jester]

Originally Posted by matzell

I am sending my registration in this week for GSMTR.

My GSMTR registration is on the counter waiting for a check (need to get the wife involved for that ). If I keep up the pace of the last couple of weeks, I might make it.

Somebody, who should remain nameless should his wife read this and realize that he wasn't working late at his paying job, came by tonight and helped me bolt on the freshly painted sliders (HEAVY!!!) and give the cage a test flop. At least I can put some nice welds on the bottom now and get it painted. (I'm not good upside down with a MIG - especially on round tube). The pups needed to come see what I was up to. Einstein looks concerned - I told him he got to ride in the back and he doesn't see enough bars back there.

[cruiserjohn]

The cage is looking good. get it welded and back in so you can jump to the next step of the build. Waiting to hear it run .

[smtyblt]

Looking good just might have to work late friday!!!

[Jester]

Originally Posted by smtyblt

Looking good just might have to work late friday!!!

Nice, I'll be here burning away.

BTW, just ordered a ton a pre-punched steel brackets and tabs for seat belt mounts, cage gussets, and shock tabs from a company called A&A Manufacturing. The 3-hole gussets were only $0.23 each!

[cruzer75]

Tim, the 40's looking great, good job on the cage, can't wait to see it wheel in May,
Fred

[nweiv_78fj40]

Looks good. Now all you need is some paint and you should be ready to roll. (right side up that is)

I can't wait to see what you break first. Are we taking bets on who rolls first at GSMTR?

BTW I'm going to GSMTR, but I t hink I'm going to ride shotgun with Rob. Or at least that's what planned. I still have a my permission slip all filled out and ready to go, but I'm thinking things may be tight after a trip to Europe in April......

[smtyblt]

Originally Posted by nweiv_78fj40

Looks good. Now all you need is some paint and you should be ready to roll. (right side up that is)

I can't wait to see what you break first. Are we taking bets on who rolls first at GSMTR?

BTW I'm going to GSMTR, but I t hink I'm going to ride shotgun with Rob. Or at least that's what planned. I still have a my permission slip all filled out and ready to go, but I'm thinking things may be tight after a trip to Europe in April......

suck it up and put the Credit Card in to meltdown mode

When will the next time almost all of the wheeling members of BBRC going to be at Telico much less GSMTR at the same time?

[nweiv_78fj40]

I know, I know.....I got the kitchen pass, just need to make the decision. What is everyone's schedule? When is everyone going? I know Rob is leaving from Richmond on Wednesday night after work, and I know I could probably leave earlier in the week...if I have the time off.

I like the idea of white water rafting on Wednesday....

Norm

[Jester]

I didn’t get as much done this weekend as I would have liked…

We got the cage fully welded, including some kickers on the main pillar to halo. I’m waiting for my gussets and seat belts to come in before I paint it. (I ordered some gray harnesses from Crow Enterprizes, 3” lap & 2” shoulder, should be in this week.)

I spent most of Saturday modifying the mini-truck shifter for the Toybox so it wouldn't hit the other shift levers. I ended up just using the part that sticks into the case, which I bent in the press to work. The rest is some ¾” tubing, a 1/2x13 bolt and some MIG wire. I finished grafting a FJ60 hump cover to my cut-up FJ40 tunnel. It turned out okay after paint.

Also got my Summit 100Amp, 1 wire Alternator installed on a March bracket. That was one thing I needed to do before I fire the engine, since I need a belt to run the water pump.

[Jester]

Originally Posted by nweiv_78fj40

I like the idea of white water rafting on Wednesday....

Norm

They should show this on Tuesday night

[smtyblt]

The Tranny hump looks good man

[Klunky Chris]

lookin good Tim!!!!



glad that everyone seeing my 40 actually exists and was on the trail (except for Heffenoche of course....) gave you the kick in the rear to get yours on the trail!!!


gonna be sweet when you're done!