Hi all. Wanted to share my exo cage build for my '99 XJ. I started this back in July (when I got going on the drawings and such) and finally got it finished up this weekend.
I started with doing some 3-D work in Rhino to get a rough idea of what I wanted it to look like, and to get some idea of how much tubing I would need.
One of my criteria when thinking this out, was to be able to have the cage removable, or at least most of it, just in case the need arose.
I used the C-rok cage that he used to build as sort of my "inspiration."
Before getting into building the exo, I figured I should do some beefing up of the sub structure. I decided to plate the frame rails using 3"x3" angle iron (1/8" thick). In reading here, most people said 1/4" was way overkill, and even 3/16 was a bit thick. I also found some pretty useful info on this site:
http://1997jeepcherokee.blogspot.com/2007/01/frame-stiffeners.html
I cut the angle so I could match the change in height of the frame rails. I drilled 1/2" holes about every 6" for plug welds. I marked where existing holes were in the frame rails to make sure my plug welds weren't on top of those. I welded up the front and rear ends, and then stich welded the edges to the existing frame rails. I tried to get these stiches to alternate the plug welds.
Since the cage tied into the sliders, and then into the frame rails, I figured I better beef up the attachments between those. (by the way, I started with the C4x4 rock rails I have had for a couple years.) I welded the front mount to the new plated rails, and added three more cross pieces to each side (1.75" .12" wall HREW tubing.)
My front bumper started as a Trail Ready. The ends got pretty worked over the past two years, so I cut those off, welded the frame rail attachments to the bumper (used to be bolted), and welded on new wings using a mix of 2" square tubing and more 1.75 round tubing.
The rear bumper I built last winter, and am pretty comfortable in how solid it is, and using it as a rear attachment.
I started with doing some 3-D work in Rhino to get a rough idea of what I wanted it to look like, and to get some idea of how much tubing I would need.
One of my criteria when thinking this out, was to be able to have the cage removable, or at least most of it, just in case the need arose.
I used the C-rok cage that he used to build as sort of my "inspiration."
Before getting into building the exo, I figured I should do some beefing up of the sub structure. I decided to plate the frame rails using 3"x3" angle iron (1/8" thick). In reading here, most people said 1/4" was way overkill, and even 3/16 was a bit thick. I also found some pretty useful info on this site:
http://1997jeepcherokee.blogspot.com/2007/01/frame-stiffeners.html
I cut the angle so I could match the change in height of the frame rails. I drilled 1/2" holes about every 6" for plug welds. I marked where existing holes were in the frame rails to make sure my plug welds weren't on top of those. I welded up the front and rear ends, and then stich welded the edges to the existing frame rails. I tried to get these stiches to alternate the plug welds.
Since the cage tied into the sliders, and then into the frame rails, I figured I better beef up the attachments between those. (by the way, I started with the C4x4 rock rails I have had for a couple years.) I welded the front mount to the new plated rails, and added three more cross pieces to each side (1.75" .12" wall HREW tubing.)
My front bumper started as a Trail Ready. The ends got pretty worked over the past two years, so I cut those off, welded the frame rail attachments to the bumper (used to be bolted), and welded on new wings using a mix of 2" square tubing and more 1.75 round tubing.
The rear bumper I built last winter, and am pretty comfortable in how solid it is, and using it as a rear attachment.
. I found a few different 3-D files. I am pretty sure the one I used was a .3ds. I think there are some in the google Sketchup 3-D warehouse. It should transfer to soildworks. I wil probabaly not hand out my working portion of it, but the stuff I found online, shoot me a pm with e-mail and I can send anyone anything I have.
