Replacing an old cage with a hybrid - HD Offroad Engineering

[Pat]

Here is a quick look at the changes BrianHo and I made to my rig over the past few weeks. I had an old EOR cage kit that went in back in '05 right before the Fall Flog down in Tellico. It was a decent cage, but I didn't really like it for a few reasons:
- the top of my head was really close to the headliner and I have always worried that the cage wouldn't keep the sheet metal and thus, ground, away from my head in a good roll
- the tube work didn't conform to the body lines very well, and really obstructed my visibility (pic below)
- due to the overhead spreaders being internal, the driver's side spreader was really close to the side of my head (it was padded) and also blocked vision out of the driver window
- the cage wouldn't preserve the body in a roll
Old cage:

This sucked:

I really loved these sliders and was sad to see them go:

Out with the old:

 

[Pat]

So, I decided it was time for a hybrid cage. I really wanted to make sure I was pleased with this one, and wanted it to fit tightly to the body. Here is what we came up with...this is all 1.5" DOM, .120 wall...
Raised up a bit in the Ho garage:

No bends in the down tubes. Both B and D run through the roof. B pillar placed in the same spot as the previous so it would tie into the spreaders that connect my rockers to the frame rails.

In the meantime, I painted the roof halo, cross bars, a pillars, etc and pulled the fenders. Brian came up to my place for some front end tube work and to finish out the interior.

A pillar to rocker:

Just barely clearing the front bumper, and tall enough to protect the radiator:

Interior work:

 

[Pat]

Ahh...much better:

Tight fit:

I love the way it turned out and can't wait to drive it with the increased visibility (there is also a new windshield in there), interior space and protection. Just have to fit the harnesses and fenders and paint it all up. Will update once I get to that.

Huge thanks to Brian for his time, patience and great work on this. :cheers:

 

[FlexdXJ]

Damn, Looks Awesome Pat! I love the look of a hybrid cage but I still want to be able to throw something on the roof and have all my seats functioning properly. So I don't know how my eventual cage will be. But brian does great work so I will keep him in mind for building mine.

 

[Pat]

Thanks - it could be built to allow crap on the roof and to let passengers in the back. I just don't want anything on the roof and don't like having more than one passenger.

I have the B pillar tube so far back to make room for me up front. Most could move that up closer to the body B pillar to make more room for more passengers...

 

[FlexdXJ]

Thanks - it could be built to allow crap on the roof and to let passengers in the back. I just don't want anything on the roof and don't like having more than one passenger.

I have the B pillar tube so far back to make room for me up front. Most could move that up closer to the body B pillar to make more room for more passengers...

I'm just thinking from a its still my DD perspective. On the trail, I don't like a lot of passengers either. I'm sure we could come up with something.

 

[clayttrwku]

Looks great Pat!

 

[IllianaXJ]

Looks great Pat, Brian does some great fab work. I like the tie-ins to the sliders, the fender bars look familiar too; much more direct than mine were though.

 

[StylerG]

thats exactly what im looking for in a cage! Love the front design and roof, only thing different would be to allow for backseat passengers for me. Looks good, congrats man.

 

[XJ&CHZ4ME]

Thanks - it could be built to allow crap on the roof and to let passengers in the back. I just don't want anything on the roof and don't like having more than one passenger.

Looks awesome Pat! I quoted the above statement because that is EXACTLY how I feel about it as well. That is a very cool and clean set up, you guys nailed it.

Cheese "my junk is not worth redoing the cage or roof sliders again" Man

 

[kmanxj5050]

looks good really trying to decide on an internal or hybrid cage. But my roof is already jacked up so idk.

have pics of how you tied it to the unibody?

 

[Pat]

There is a plate sandwiching the floor with the B pillar foot plate. By design, the foot plate is directly above one of the connectors from my 2x6 rockers to the plated frame rails. There are then just small tabs welded in place to attach each side of the connector to the lower foot plate. The A pillars welded to the rocker are the other tie ins to the unibody.

 

[bmyohn]

Very impressive Pat! I look forward to checking it out!

 

[rkates]

Looks great man, I have one question about it though. Is there a reason the bar above the windshield doesn't fallow the body line up and over like you did the rear bar?

 

[cabjeepster]

Looks good man. Brian does good work.

 

[REWSTER]

Looks great!!

 

[commsys]

Looks great - So.. seeing as I can't what tire size and gearing to upgrade to, the thought of a cage was kind of next on the list.
Any idea how much tubing you used??
Also, welding technique -TIG, MIG, gas?

 

[BRIANHO13]

Welding was mig, for this cage we used right at 120-130 ft.

 

[John D]

I like it, I'm kinda partial to hybrid cages though

When you mount the fenders will the tube be completely covered?

 

[hanaxj87]

Man,that looks good.Nice job Pat and Brian.

Nick