horrible crash right outside my work this morning...

[jw0747]

mine has a full family cage. you can talk about cage designs all day long and hope they prevent death and injuries but the best protection available is for all people inside to be belted in, slow down, be totally observant to traffic conditions and don't get distracted by adjusting the radio, checking your phone emails, texts, dialing or applying your make-up etc. good sense when driving is better than any roll bar out there.

 

[Revelation]

This is a thread of what Broncitis was referring to with his cage punching thru the floor. Post #6 is the picture but the link to the video is dead.

The area that failed on his was a poor design from Ford. the way they pieced together the bed section for Broncos is bad at best. Attached are drawing of one of the areas that failed in that roll over. Only way to strengthen a roll bar mounted to those filler pieces would be to tie it to the frame.

 

[Hank_]

This thread makes me want to leave my bronco unfinished in my garage and drive my f150 with air bags.

Henry

 

[lowbush]

This thread makes me want to leave my bronco unfinished in my garage and drive my f150 with air bags.

Henry

That or just get a set of these

 

[NY-Bronco]

One of my reasons for doing a major rebuild on Gumby is the safety factor of the whole thing. My biggest worry was being speared by the steering column as well as getting crushed during a rollover.

Im trashing my stock steering column in favor of something collapsible and currently discussing the roll cage options.

Ive been looking at all bolts and joints on the EB and most of it is getting redone. Thankfully I have Jay to do the fabrication. Unlike me, he is a master at what he does.

I really like the idea of people inspecting each others rides at the major events.

Prayers for all involved in the accident.

 

[jim3326]

The area that failed on his was a poor design from Ford. the way they pieced together the bed section for Broncos is bad at best. Attached are drawing of one of the areas that failed in that roll over. Only way to strengthen a roll bar mounted to those filler pieces would be to tie it to the frame.

This is the way I'm tying the cage to the floor at the B-pillar. I'm also going to put in floor bars for the seats and harness.

Jim W.

 

[Mountain Ram]

I do not think the design in the pics in post #74 with the bushings were a result of an intentional engineering decision for a "crumple zone" effect.

From those I have seen build them this way, they are often done to allow for some flex in the chassis and for easier alignment than 100% ridgid mounts in case you remove and re install.
.

I didn't mean they were design as a crumple zone, but would allow for a similar effect. The bushing's engineering effect is to allow for frame twist. Has been very common in off road racing (or at least was common).

I remember your roll (didn't witness it in person), and that video should be posted and stickied.

From an engineering and safety aspect- crossbars would be priority one and I would do frame tie ins as well.

Todd

 

[sprdv1]

This thread makes me want to leave my bronco unfinished in my garage and drive my f150 with air bags.

Henry

Heck no, Drive it, Enjoy it...

 

[jlylec]

I'm trying to figure out what kind of cage to put in my new EB and found this thread. Scary. Definitely not riding my girls around over 25MPH until I get this done.

I'm really leaning towards the Baile Family Custom cage at this point. It seems to be the most complete and well-thought-out cage I have seen to buy online. I'm sure it would cost me a lot more time and money to have anything better designed and built locally. Do any of you know of any cage that is better for whatever reason?

Also...on the weight issue affecting handling and ride...what can be done to compensate for this? Beefed up suspension? Seems like a small price to pay (handling and ride) for roll-over safety in a vehicle that is prone to roll over!

 

[Greg_B]

Weight is an issue... I was amazed at how it adversly affected the handling in mine when I put a full cage in.

Since then I have thought about it more and I think if I were doing it again I would use 1.75 wall tube and 1.25 for the seat tie ins on the floor. Not sure I would change my design much other than going a little lighter.

Seats and seat belts are very important as well.... and how they fit the occupants.

Greg

 

[rustbucket]

If you build the cage out of chromoly tubing you can use thinner walled material to obtain the same strength in a lighter assembly. You can save about 35% in weight. Costs a lot more, though.

 

[lowbush]

If you build the cage out of chromoly tubing you can use thinner walled material to obtain the same strength in a lighter assembly. You can save about 35% in weight. Costs a lot more, though.

And it has to be heat treated, so you have to have a shop with an oven.

 

[blubuckaroo]

This thread is like a comedy. You're trying to make an old car street safe by addressing only the issue of the top getting crushed? You're adding hundreds of pounds to the top of the car? I think you just made it less safe. I can understand a cage for rock crawling but on the street, stability is more important.

 

[jlylec]

This thread is like a comedy. You're trying to make an old car street safe by addressing only the issue of the top getting crushed? You're adding hundreds of pounds to the top of the car? I think you just made it less safe. I can understand a cage for rock crawling but on the street, stability is more important.

i'm not sure it's an accurate statement or implication that an EB is safer without a roll cage because the weight of the cage causes the truck to be less stable and more prone to accident. even if this IS true aren't you better prepared WITH the cage? it's not as if without a cage a bronco rides on rails. they're still pretty top heavy and without a cage in a bad accident your chances of surviving are greatly diminished. no?

I'm not trying to put words or thoughts in your mouth/head...this is just how I'm reading your post. I'd rather not have to spend a grand or two on a family roll cage...and while I don't mind the way they all look, I'm just as happy aesthetically without one. But I do want to maximize the safety of the truck. Do you have any tips on improving stability?

I'd spend even more money on ensuring the truck will never roll over, but I don't think they sell that!

 

[Revelation]

My Bronco has a 3.5 lift and a 1" body lift, I lowered the motor 3" and moved it to the rear 3".
Yes she is stable on the corners, has a great feel going down the road. Of course with the 300 six and NP435, no top and a roll cage it moved a huge chunk of the center of gravity to the center of the truck.

 

[SP66]

Double shock / stock hoop mentioned--in terms of safety on the street--could you guys educate me--

 

[jlylec]

Double shock / stock hoop mentioned--in terms of safety on the street--could you guys educate me--

yeah I'm very interested in things like this as well. I'd like to make sure I beef up the stability of my truck as best I can. I just bought it and it has like 5" of suspension lift and 2.5" of body lift...running 35x12.50s. it looks really good, but i know i should lower it to get the center of gravity down. the only problem is the suspension is all new and it looks like the body lift was a necessity to fit the long travel hoops in. otherwise i would at least take that off and lower it a couple inches. as it stands i guess i'd have to swap out the entire suspension to get it lower.

 

[lil bronco]

This thread is like a comedy. You're trying to make an old car street safe by addressing only the issue of the top getting crushed? You're adding hundreds of pounds to the top of the car? I think you just made it less safe. I can understand a cage for rock crawling but on the street, stability is more important.

Like a COMEDY

I don't think so?:?

 

[zonian]

Tragedy, regardless of how it happened. I have experienced the "death wobble" and even after many years and a few car crashes it is still one of the scariest moments Ive ever had driving. This thread made me think, any advice on upgrading the cages, etc. is worthwhile. I now know my 16 year old aint ever driving the bronco, its one thing if I get taken out, but couldnt handle if anything happened to him or someone else. My prayers to the families....

 

[67RT]

The area that failed on his was a poor design from Ford. the way they pieced together the bed section for Broncos is bad at best. Attached are drawing of one of the areas that failed in that roll over. Only way to strengthen a roll bar mounted to those filler pieces would be to tie it to the frame.

What area is this diagram depicting. I just purchased a rear family cage and want to make sure it is secure. Toms said most just secure to floor but if it is a weak part I want to tie in..