Getting Cagey...

[HillBillE]

Two friends and I went in on building a bender. Our buddy Russell built it and also bought the Bend-Tech computer program. The program is awsome! With a few measurements, we deisigned my cage this morning, and got started on some bends.
I'm going with a complete new cage, not using the factory bar at all.
My main concerns were to be able to still use the hardtop,use the hard doors, have a 'family' style full cage, and not have the A pillar interfere with swinging my feet in and out the door opening. Looks like I'll not only have that, but have the use of my (stock) window cranks, glovebox and grab bar above the glove box.
Here is the design we came up with using the Bend-tech program:
http://i112.photobucket.com/albums/n190/russellmn/hillbillecage.gif
The 2 main bars: Along with my helper, my oldest son Ty.
http://i112.photobucket.com/albums/n190/russellmn/SS850086.jpg
http://i112.photobucket.com/albums/n190/russellmn/SS850091.jpg
Window crank still clears!!!! Usually you have to get shorter crank handles or open the door to roll it up and down.
http://i112.photobucket.com/albums/n190/russellmn/SS850090.jpg
http://i112.photobucket.com/albums/n190/russellmn/SS850089.jpg
http://i112.photobucket.com/albums/n190/russellmn/SS850084.jpg
http://i112.photobucket.com/albums/n190/russellmn/SS850083.jpg
http://i112.photobucket.com/albums/n190/russellmn/SS850082.jpg
Going to also run a bar behind the seatbacks, for the 4 point harness', and that will get triangulated (it's not on the design pic yet.) And run spreaders at the bottom between the A and B pillars, along with a couple cross bars for mounting the seats and lapbelt portion of the harness.
Of course this will all be tied into the frame.

Going to work on it some more tomorrow, and I'll post more pics as I go.
The last thing we did tonight was set the hardtop back on. The cage fits nice and tight inside, without actually touching the top.

[miljeep]

Looks pretty sharp. I wish I had the knowledge, skill and tools to be able to do that.

[ArmyFSJ]

lookin good man

[vajeeper]

Sweet...

[BESRK]

Awesome! Isn't Bendtech great!!? I won't hardly bend a single piece of tube without it. I love the "verify" feature where you can pick points along the tube and check distances to make sure something is gonna fit before you ruin it.

It's funny, you're like one-step ahead of me all the way. I'm working on rewiring some things, then it's on the finishing the cage, doing tube fenders and shooting paint.

Are you going to use a tube notcher? I used to just cut/plasma/grind the tube ends for fitup but a nice notcher will make things sooooo much easier. Even one of those cheap Northern Tool notchers are worth it just to do one cage.

[HillBillE]

Russell has a notcher, and I'm going to pick one up. I'm going to be finishing my cage at home, Russell lives 50 miles away, so what I'd spend in gas to run back and forth will pay for one of the cheap notchers.

The Bend-Tech program is incredible! The only waste we hd was from our own error in rotating the tube between bends, after figuring that out, it was a breeze! For the 2 main 'hoops', we left and extra 2'' on each end of the tube. After bending we cut exactly 2" off each end! No waste at all!

Hey BESRK, tube fenders? Thats funny! I just need to add the flares and clean up and paint mine!
Mine are more 'flattie' style, but the flare will be tube and 16 guage strips 3'' wide.

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/Fenders-cage005.jpg

And I have the wiring under control, so far:o It can be a pain! I ripped out everything from under the dash that wasn't factory, including wires from the PO and myself. All extras lke the radio and CB will now run right from the battery, with a breaker and main shutoff. No more splicing into any wire harnesses. Going to head out and do some more work on the cage today, be back with some more pics tonight. HB

[Truck]

Both of you are moving right along...looks great! Awesome that you worked around the pesky window crank and glove box.

Truck

[HillBillE]

Got a little more done.

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/Fenders-cage013.jpg

This is the fit up of the joint at the top of the pass. side B pillar:

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/Fenders-cage011.jpg

[korisu56]

That fitting is really clean. Awesome work.

[TexCJ7]

where do you get the hole saws for cutting metal i have some general purpose ones but the wear down fast

[BESRK]

Regular Bi Metal Hole Saws.. Dewalt, Milwaukee, Lennox..etc.

The key is to apply enough pressure for the saw to take a good "chip". If you don't push hard enough, the blade will just spin, get hot, and ruin the teeth. I also use a "misting spray coolant" which helps prolong life a bunch. I've got one hole saw (1.5" dia) that has probably drilled 200 holes thru 3/16" thick plate.

That's a nice joint. Those make welding soooo much easier.

[TexCJ7]

thankx thats probly part of my problem they don't have those brands at harbor freight, i guess you end up spending more when you try to buy cheap

[korisu56]

buy it nice or buy it twice.

[HillBillE]

Put in the A-B spreaders and seat tie in bars:
http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage015.jpg
And figured out a way to clear the wiper motor cover and still use the fan knob:
http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage018.jpg
And one of dash bar and me, taken by my 6 year old.
http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage019.jpg

[BESRK]

Looks great!

You're pulling into the lead! Just wait though.. I'm putting in a full day tomorrow! :D

[HillBillE]

Pulled the cage today, finished the welds and threw some paint on it.
I still need to weld on the seatbelt mounts, but I'm going to wait until both seats are mounted so they are where I want them.

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage025.jpg

Jeep looks funny, must be that nifty red driver seat! :D

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage022.jpg

[korisu56]

What's wrong with that? She looks ready to go wheelin!

[TexCJ7]

thats sweet and i can't wait to see that roll cage in my jeep

[HillBillE]

thats sweet and i can't wait to see that roll cage in my jeep

Ow! That would be one hell of a crash to fit that (along with my Jeep) into yours!:D

It's a little different than the original design. I put a tube at 45 deg. between the B pillars, and left out some of the tubes on the top 'halo'.

[russellmn]

Hey guys, I'm Russell, the poor sap that has to put up with HB while bending up his tube/wheeling/bench building whatever. :D
I'll be posting my build on here as soon as I finish up another CJ7.

[miljeep]

welcome

[russellmn]

HB, you gonna put that cage back in today????

[HillBillE]

No, I'm going to Herculine the inside of the tub first, along with my tube fenders. So I need to finish the fenders and prep them and the tub for the Herc.

And of course, I ran out of gas for the MIG right away this morning.

I went with a larger (size S) tank like yours, and still have the small one for 'traveling' with the welder.

[russellmn]

haha, I ran out of gas tonight too! Getting closer on Matt's rig tonight, I'll be working alone on it this weekend, Matt has some family stuff going on.

[HillBillE]

haha, I ran out of gas tonight too! Getting closer on Matt's rig tonight, I'll be working alone on it this weekend, Matt has some family stuff going on.

Thoght you had Guards this weekend? I'll be down Monday round 10, I have a root canal at 0700, flippin yeah!:eek:

[HillBillE]

Got the tub and fenders Herc-U-Lined, and got the cage in and fenders on.

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage033.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage042.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage044.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage052.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage051.jpg

The cage is mounted to the tub, (sandwiched with 4x4'' plates on top and 5x5'' on bottom) Ready to be tied into the frame. Really wanted to drive it home tonight, and start getting some miles on the rebuilt engine and new gears/lockers.

However it decided to start raining, and the temps are around 20 and dropping. Didn't want to take it out with the salt on the roads, not to mention I'm not used to driving with a locker in the rear, it's squirrely enough without freezing rain!:D

[korisu56]

That thing is looking mean.

[02tj]

Freakin awesome work bro!!!!!!

[HillBillE]

Thanks guys! I put the top on this week, it fits great! Really tucked up tight into the top.

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage062.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage060.jpg

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage059.jpg

Now I just have to tie it into the frame. I plan on using the tops of 2 old main hoops for 'nerf bars', and tying the cage into those.

[HillBillE]

I finally got around to tying the cage to the frame. I used the top portions of two CJ rollbars for 'nerfbars' (fit perfect!) and tied the cage into the bars.

A pillar tie in:

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage071.jpg

B pillar tie in:

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage072.jpg

Nerf bar to frame:

http://i114.photobucket.com/albums/n274/hillbillecj7/CJ%20Rebuild%202%20Dec07/fenders-cage073.jpg

I stil need to tie in the back, or C pillar mounts.

The cage sandwiches the tub, using 4"x4" plates on top and 5"x5" plates on the bottom, to avoid the 'can opener' effect. There are three 7/16'' grade 8 bolts at each plate. I can feel some vibration transferred up through the seats, but nothing bad fo a CJ:D

[Hitechredneck]

looks good man nice cage.

[BrockGrimes]

Old thread but which Bend-Tech program do you suggest using or have used?
Cost?
Anyone have plans to a good quality home built type bender?

[BrockGrimes]

No one? :confused:

[russellmn]

Brock, we used BendTech Pro. Pro is the lowest cost program that allows you to do assemblies rather than individual parts. i.e. an entire cage rather than one tube of the cage. It's around $300, don't remember exactly, but worth every penny.