Internal roll cage fab - Defender Source
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  #1  
Old March 20th, 2009, 10:25 PM
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Peter Stolz
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Internal roll cage fab

I'm finally getting around to posting these pics if anybody's interested. Jim Pace (a forum member here), my wife and I ruminated a lot over the design, and basically, the goal was to protect the rear passengers (in four jump seats) and look consistent with original factory bits. It was fabbed up by a local guy named Leroy who really did a spectacular job. (He also fabbed up a winch mount, but I'll save that for the sequel.) It actually protects the front passenger much better, too, because the POE's didn't come with a B-pillar bar over the top--the external cage is just bolted to the aluminum top with no real support on the inside as most of you already know.

As you can see from the pics, it's tied to the W-bar, the external cage, and to the original cage structure that goes under the truck amidships and aft. The little tabs in the top corner of the B-pillar bar are gone. Originally I planned for the tabs to be the seat-belt anchor points for the forward-most jump-seat occupants. As I was installing the belts, I found a better point right on the vertical part of the same bar. I just drilled and tapped a hole where the steel is double thick at the connector collar. I have no empirical crash-testing data, but it just looked like that tab might want to find it's way into a front occupant's head in a catastrophic situation. The tabs in the corner of the C-pillar bar work perfectly for seat-belt anchors.

I had to make sure the C-pillar bar was forward enough so the rear-hatch hinges would have clearance to allow the hatch to close. The two bars on top running fore and aft between the B- and C-pillars were located there to give the jump-seat passengers as much head room as possible, and also so the alpine windows would not be obstructed. For lack of a better alternative so far, I've since put cheap pipe insulation on the bars as padding. Not ideal, but a head saver for sure.

The bars are all removable except the B-pillar vertical bars. Those had to be welded to the existing bar that comes up from the W bar, because Leroy didn't have enough clearance to weld a collar in between the bar and the aluminum top. All the collars are bolted together with two "C" type deals just like the factory's cage joinery. One of them is welded to the end of a bar on either side of the joint, and when assembled they meet and mate and bolt together in wedded bliss. It's a beautiful ceremony. (I told myself I wasn't going to cry...)

BTW, these photos show some stuff that's not right but have been fixed--like the twisted seat belt, rusty brackets, etc...just so you know.

Big thanks to Jim and Leroy for all their help. Now we can get dirty safely!

Pete
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  #2  
Old March 23rd, 2009, 08:45 PM
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Scott
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That is exactly what I want to do with my SW... Thanks for the great pics.

Scott
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  #3  
Old March 30th, 2009, 06:05 PM
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Jim Pace
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Pete,
Looks great. Safe, clean and simple. Super job on following through with the project.
Jim
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  #4  
Old March 31st, 2009, 09:26 AM
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Charles Galpin
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I love it. Did he do it all ad-hoc, or does he have cad drawings of the design?
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  #5  
Old March 31st, 2009, 09:41 AM
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Peter Stolz
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Well, I talked with Leroy about what we wanted and he pretty much made it up as he went along. No cad stuff though. It ended up exactly as planned. If you want more pics or a different angle of something, I'd be happy to provide them. Just let me know.
Pete
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  #6  
Old March 31st, 2009, 09:47 AM
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Charles Galpin
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Thank Pete

If you have any shots of the assembly in progress, and/or close ups of the "C" joints I'd love to see them.

I want to do some interior cage work on my 110, and would like to make it bolt in like you did, trying to keep the joints as similar to the LR ones as possible.

thanks,
charles
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  #7  
Old March 31st, 2009, 09:58 AM
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Peter Stolz
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I don't have any of the assembly as it progresses, unfortunately, but I can get some of the joints later today or tomorrow. It's basically my daughter's daily driver, so I have to wait till after school/work/boyfriend/whatever.
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  #8  
Old April 8th, 2009, 01:47 AM
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Peter Stolz
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So, here are some pics of a couple OE joints and a couple of the ones we fabbed up. Hope those help!
Pete
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  #9  
Old April 8th, 2009, 08:10 AM
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Charles Galpin
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Thanks Pete

I'd love to do the OE style bend in the strap instead of the half tube and tab, but that would certainly work.

With the right setup I imagine someone could crank these out at a reasonable price - probably no demand though.
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  #10  
Old April 8th, 2009, 08:45 AM
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Quote:
Originally Posted by cgalpin
Thanks Pete

I'd love to do the OE style bend in the strap instead of the half tube and tab, but that would certainly work.

With the right setup I imagine someone could crank these out at a reasonable price - probably no demand though.
There has got to be a source or a fab shop already making them. It would be pretty labor intensive to cut some tube and add tabs - makes for a weaker setup anyway....

I am going to give Iron Pig Offroad in Fredericksburg a call.
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  #11  
Old July 13th, 2009, 02:34 PM
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Just finished a Jeep Grand Cherokee internal/external cage. Here are the roll cage clamps I've started using. They are a little pricey at $30 list price, but seem much stronger to me.

http://www.ballisticfabrication.com/...mp_p_1467.html#
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  #12  
Old July 13th, 2009, 04:33 PM
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cool. any photos of the cage?

Quote:
Originally Posted by Wolf Fabrication
Just finished a Jeep Grand Cherokee internal/external cage. Here are the roll cage clamps I've started using. They are a little pricey at $30 list price, but seem much stronger to me.

http://www.ballisticfabrication.com/...mp_p_1467.html#
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  #13  
Old July 13th, 2009, 05:39 PM
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Originally Posted by Ren Ching
cool. any photos of the cage?
I'll try to scare some up.
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