Build 4 door Fj45 on 80 series chassis

[Blackknight1]

Like peesy said, do it right or don’t do it.

Very common in these trucks is 1.75” .188 wall 1020 DOM tube. Not pipe. .120 wall might be common too.
Every race federation has their own rule book, and a lot can be learned from these rule books, but the rules don’t apply to us just driving our trucks around looking for some extra protection. But the knowledge is there.

I don’t think the weight would be a factor.

You need to use a mandrel bender, one that pulls the tube around a die, not a hydraulic thing that pushes the tube into a shape. It’s going to kink or at least lose a lot of strength.
I have a JD Squared, Rogue Fabrication is also a very popular one.

In a 40 the best looking cages in my opinion are the ones that wrap tight around the dash lines and the roof curves. It takes a good bender and a lot of forethought to do that. A subscription to Bend-Tech software really helped me visualize and fit stuff.

If you can remove the roof easily enough and you’re not dead set on a cage right now, you could wait until later to do it.

Another thing that complicates proper cage mounting in my opinion is that it needs to not be mounted to the floor or tub, but through the floor, allowing for the same flex as the floor and tub but not depending on it for strength, but going to the frame. At least that’s how I wanted mine with my aluminum tub.

Great. Thanks to both of you for the answers. I don't have the right material ,the tools or the knowledge. No cage for me. At least not for now.

 

[Blackknight1]

Went to the shop today and I worked on the truck some more. That 80 series donor became the gift that keeps on giving. We took the fuel ️ inlet system from it and started installing it on the 45. No..... it is definitely not plug and play. It'll take a bit of cutting...... quite a bit of welding, but it is definitely doable. I took a few pics that I'll post here . The finished product will be posted when finished this week.