My Family Cage build thread (FINAL PICS PAGE-4)

[bigcountry]

Very nice. I am thinking of building my on cage. What kind of bender is that, and where did you get it?

 

[JDJ]

cage is looking good

 

[TTTGOWYO]

Wow... I love the front legs how they match the angle and don not interfere with the glovebox or wing windows.. amazing work..

 

[xcntrk]

Wow... I love the front legs how they match the angle and don not interfere with the glovebox or wing windows.. amazing work..

Thanks... I'll have to cut the glovebox liner as the bar will interfere with the right most corner of it. But overall I will still have a functioning glovebox for now.

The original dash is only temporary. One day in the future I plan to build a custom dash with all new gauges, switches, etc. So I wasn't too concerned with re-finishing this dash after the significant notching. Also you may notice on the driver side I had my headlight, wiper, and manual choke right where the pillar leg comes down. I'll have to relocate those somewhere as they won't fit any longer. Again just a temporary relocation until I rework a new dash...

 

[Bronco_69]

very nice!!

 

[aaron6920]

Too Cool Nice Job, lots of work

 

[quikdrummer]

That is awesome.

I have the same welder, love it. I'm trying to talk the wife into letting me get a bender aand notcher so I can do what your doing ;D

Great work, keep the pics coming!

 

[xcntrk]

Front seats are done. Floor crossmembers, seat tabs, sliders and mounts.

 

[JDJ]

nice job

 

[xcntrk]

Man these through the tube seatbelt bungs are really nice. This is a crossbar that sits on the floor behind my rear bench seat and these are the receiver mounts.

First you cross drill the tube the exact diameter of the bung:

.


The bung should insert through and the shoulder on the base of the bung is larger than the hole and can't pull through:

Then you weld both the butt and the front end of the bung:

So in order for these to fail you'd have to break both welds then pull the oversized shoulder through the tube. I think you stand a better chance of pulling the bolt through the threads then this bung separating from the tube.

 

[xcntrk]

Modified Ebrake Bracket

Keeping it going...

Here's my modified Ebrake lever bracket. The A-pillar leg on the drivers side comes down through the dash along the very edge of the cowl and prevent the Ebrake from mounting in the original location. The leg is very tight against the kick panel area of the cowl and the Ebrake only needs to move over about an inch to clear. I've seen a number of different ways to address this. Some of the most common are; bend the bracket over so it mounts at an angle between the dash and firewall, or enlarge the Ebrake foot pad so you have enough room to engage it around the tube.

Neither of these work for me and since all I needed was to move the entire bracket over an inch, I simply cut off the tail of the bracket where the 90-degree angle and mounting studs exist. I then flipped this over and welded it to the other side of the bracket and I added a simple gusset for additional support. This leaves the rear of the bracket to mount in the original holes but moves the entire unit over 1". I then drilled a new hole in the bottom dash for the front of the bracket. The whole thing now clears the leg and and continues to run forward to back without any weird angles.

 

[deltarat]

Very nice. I am thinking of building my on cage. What kind of bender is that, and where did you get it?

I was wondering that as well.

 

[xcntrk]

Oops totally missed that question. It's a Pro3 hydraulic tube bender and dies from Pro-Bender. They have a number of various discounts and promotions on Pirate 4x4.

 

[xcntrk]

Almost done.

 

[RV77]

Would you be interested in doing another ?

 

[xcntrk]

Finished with all the assembly, final welds, and clean up. Now off to the powdercoaters...

A few pics of the finished cage in raw form.

Passenger side view:

Front view:

Rear view:

Top view:

Seat belt bungs:

Front seat & center console tabs:

Gussets:

Bungs for windshield braces:

 

[JDJ]

looks good

 

[TTTGOWYO]

Can I say again, great job on this. Very well thought out and executed. I can't wait to see it finished and in the Bronco.

 

[xcntrk]

Back from the powdercoater!

It's going in this weekend...

So close.... ;D

 

[JohnJohn]

It turned out awsome! Nice work.
Let me know if you need a hand putting it in.