Got started welding in the cage

[tjblair]

I got started welding in the cage that Justin bent up for me. thanks again Justin. I didnt have quite enough time to get it finished up but here are some pics. This is the first time I have welded up a roll cage, I think that it is going pretty well. there are a few welds that I definitly want to do a little grinding and run a second bead. it took me a little while to get used to welding around a radius. :gear_happy2:
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9070018.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9070015.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9070017.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9070025.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9070027.jpg

[limegreentj]

looks good man! nice job

[coverinearth]

just curious as to what welder/setup your using

[Mykal]

Who bent that for you? Thats pretty.

[tjblair]

justinsbig7 bent it up for me. and I was useing a hobart 140 handler using .030 fluxcore.

like I said before there are definitly a few spots I want to grind and reweld but I dont think that thing is going anywhere. I would just like those few spots to look a little better.

[limegreentj]

it looks pretty good from afar....most die hards say dont weld a cage in with a 110 volt welder....i say bullshit...if you know what you are doing you are fine...110's have a shorter duty cycle...basically means the longer you weld the quicker the weld will get "cold" or not penetrate as well...all you do is weld a bead or 2 then take a break and go do something for a few minutes then go back to it.

[96greenxjjeep]

hell yea dood looks good

[Peccavi18]

Looking good, were the PSC guessets just something you had at the shop?
Also make sure you cover your windshield or it will end up rusty like mine.

[tjblair]

Yah I just had those gussets at the shop. I thought they looked pretty good there.

And I know the windshield will be rusty but that one is already busted almost half way across so i figured that it will be replaced soon. lol

[96greenxjjeep]

when your welding the toob do you weld from start to finish or do you go halves

[tjblair]

Halves I don't know how I would be able to do it all in one shot. even doing half at a time is dificult with out re- positioning in some spots.

[coverinearth]

Looked like flux-core to me, try bumping up to .035, ive got the same welder, night and day difference between the 2 wires.

[96greenxjjeep]

we were taught both and the halves always was way way easier try like said above bigger wire.

[justin'sbig7]

glad it worked out for ya! front is looking good, i am hoping to swing in on thursday night to check out the rear halo

[tjblair]

Sounds good!

[96greenxjjeep]

ill be there too havnt been to the shop in a while

[tjblair]

ill be there too havnt been to the shop in a while

He meant my house

[96greenxjjeep]

ok then i come to your house then havnt been there for a while either

[Christopher]

Thats looking nice

[Deadman 94 xj]

Looks good Jeff. That's a nice addition to the jeep.

[Jeepin'Jones]

Looks good

[john00TJ]

looking good but you need some triangulation.

[tjblair]

There are some small gussets that are in the front that should stiffen the spreders. I just hadn't welded them in yet in the pics. But I am sure over time I will be adding a few more.

[brent66]

looks good buddy i might have to do that when i get home

[tjblair]

Got the rear window bars in tonight:o I'm still getting used to the gas mig that I have at home, and I cant really crank up the heat on the welder without blowing a breaker. So I just set it as high as I could and went real slow. I think it will be just fine though .:110:
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9090028.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9090030.jpg

[limegreentj]

lookin sexual....


BUT...i dont see the point of the rear window bars?

[tjblair]

sexual huh?

I wanted to ad the window bars to help keep stuff/people in, also I plan on putting a handle on that bar for someone to hang on. I also think that it will stiffen the stock cage. I am also thinking about putting another spreder under that diagnial bar going horizontily from the rear stock bar up to the main hoop. but I'm not sure yet.

[limegreentj]

ok i get it...it all makes sense now...haha

[tjblair]

kinda like this Brandon
http://i475.photobucket.com/albums/rr115/tjblair/August%20at%20Eau%20Claire/IMG_1291.jpg

[limegreentj]

ok i gotcha! whose rig is that? that cage is gonna be nice you are doin...might have to do one in mine...next winter maybe

[justin'sbig7]

lookin sexual....


BUT...i dont see the point of the rear window bars?


they add triangulation and support to the main hoop. the stock bar with the rounded rear bars does little to keep the main hoop in an upright position.

[tjblair]

That's the BDS tj.

[aman-fred]

I think


LOL not something you want to hear in a welding a roll cage together thread:flipoff2:

Wouldn't the window bars be stronger if the went corner to corner. I understand that the cage would have to be removed to fully weld the bottom. But then you could have done few to zero difficult welds. idk its late, need to sleep..

Looks good though jeff :thumbsup::thumbsup::thumbsup:

[justin'sbig7]

LOL not something you want to hear in a welding a roll cage together thread:flipoff2:

Wouldn't the window bars be stronger if the went corner to corner. I understand that the cage would have to be removed to fully weld the bottom. But then you could have done few to zero difficult welds. idk its late, need to sleep..

Looks good though jeff :thumbsup::thumbsup::thumbsup:


the rear seatbelts would have to be removed to take it to the corner, thats why it cuts in just above

[toocheaptosmoke]

Looks good man. I'm also a fan of flux cored, not always the prettiest but it can be strong. I had to wire up a 20 amp outlet in the garage and make a heavy duty extension cord for mine.

[mudforblood]

Lookin good.

Is the mig at home 220 or 110? Because my 110 cranked up would blow a breaker with even a 10 gauge ext. cord sometimes. I also have a small 220 mig that I made a longer 12 gauge cord in desperation and it doesn't draw near as much. I know if it was my 220 arc on that cord it would have probably melted the cord in half. The half assed cord actually worked better than I thought it would with the mig.

I bought the 110 mig first thinking it would be more versatile for yard/field repairs and the 220 actually draws less. With cords or a generator it becomes an issue I didn't think about. If your worried about your house wires a small 220 is probably more safe. I have not had a chance to look up the amp draws on all the machines, just my experience FWIW.

[aman-fred]

the rear seatbelts would have to be removed to take it to the corner, thats why it cuts in just above


Good point Justin, I had not thought about that.

[tjblair]

Got'er pretty much all done:041:, well at least it is untill I get moved into my new house and can work on it in the garage. It will do just fine untill then. Thanks again Justin for coming over to help with those few small changes I think it turned out great. Hopefully a few other people will like it enough to have you bend one up for them. :icon_super:Ok now the pics
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110034.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110033.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110035.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110032.jpg

http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110036.jpg
NOW HOPEFULLY I NEVER USE IT:023:

[Dragonslayer]

Damn dood, that cage is tight. :109:

[tjblair]

Damn dood, that cage is tight. :109:
Thanks!:023:

[limegreentj]

very nice i like it! good job to both you and justin!

[mbg]

It came out well. How does the windshield stay upright now? Does it attach to the cage still?

[tjblair]

no there are two stock screws in the hinge that you have to take out. and thanks

[Sycotik Skier]

Jeff it's really cute. Nice work Justin and Jeff

[limegreentj]

lol....cute

[tjblair]

:091:damn, first it was sexual, and now it's cute. wtf is with you queers?:102:

[limegreentj]

hey man, sexual doesnt mean queer....sexual means...like paris hilton says THATS HOT!

[tjblair]

Sexual may not mean queer, but quoting Paris Hilton is really:flamer:


:110:

[justin'sbig7]

i dig the placement of the poison spider gussets:icon_super:

[brent66]

hey i want one ill send you a msg justin

[tjblair]

Ok, so I was board today and just couldn't leve well enough alone.
so I went form this
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9110036.jpg

to this, and as requested triangles added:icon_winkle:
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9120037.jpg

and I also added a verticle spreader in the windshield
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9120038.jpg

And i had to do somthing to get my sound bar back in. So I cut up the sound bar and made custom sound pods. they fit great and I plan on taking them to work and using masking tape to plug all the holes and seal the seams and then Im going to arma coat them. That should make them compleatly air tight. and best of all I still have tunes!:035:
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9120039.jpg
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9120040.jpg
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9120042.jpg
that is all:003:

[limegreentj]

nice...i just got home man....maybe next time im out that way ill stop out

[tjblair]

Got the cage all painted tonight and I got the speaker pods coated today at work. they came out looking great and they are compleatly air tight, and they should be water tight too. Well except the actual speaker.
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9140043.jpg

and installed
http://i475.photobucket.com/albums/rr115/tjblair/jeffj%20builds/P9140046.jpg

All ready to rock!:109:

[96greenxjjeep]

sweet dood, you find a house yet

[tjblair]

yah, we close the end of Oct.

[96greenxjjeep]

sweet wheres it at

[tjblair]

near sheats on 356

[96greenxjjeep]

sweet ill have to check it out sometime

[Rubiken]

Turned out awesome smokey! I'll see you monday. He did a great job bending that up. I think those welding turned out good. I like the custom sound boxes. cant wait to see it!

[skeebs]

Good job Jeff & Justin. That cage is sweet! Stopped over to visit and never even saw this thread. When I got there, I was like....all confuse..."is this new?" Looks fantastic. And I'd love to protect my family with a cage like that.

I already told the wife I know what I want as a bday present next year. So Justin, when I have the $, i'll be in touch.

[justin'sbig7]

Good job Jeff & Justin. That cage is sweet! Stopped over to visit and never even saw this thread. When I got there, I was like....all confuse..."is this new?" Looks fantastic. And I'd love to protect my family with a cage like that.

I already told the wife I know what I want as a bday present next year. So Justin, when I have the $, i'll be in touch.

thank you for the kind words! just shoot me a pm whenever youre ready

[oldschoolyotaguy]

looks good man... you runnin flux core wire on the whole thing? what machine you using?

[tjblair]

looks good man... you runnin flux core wire on the whole thing? what machine you using?
I udsed the work welder for most or it it is a hobart 140 handler running flux core. and the rest I did at home with a little gas mig I have here.



and thanks!

[oldschoolyotaguy]

I udsed the work welder for most or it it is a hobart 140 handler running flux core. and the rest I did at home with a little gas mig I have here.



and thanks!

good deal.....i get a halfy lookin at cages.... pretty pumped to start on the cage for my zuk...im tryin to get a little rowdy with the bender haha

[gonecheenin]

That cage looks awesome in person man!

Excellant job.

[justin'sbig7]

i was thinkin, and it may be overkill, but what do you think about adding a couple of gussets in to tie the overhead spreaders to the center windshield bar?

like this

http://i48.photobucket.com/albums/f214/justinsbig7/jeffsjeep.jpg

[tjblair]

I like it! And since thr rear view mirror fell of the windshield last week end then I don't have to worry about the gussets blocking the view any more than it already was. I have to firure a way th attach the rear view mirror to the cage. Also that will give me somthing to test out the new tubeshark we got today. Well the notcher anyway.

[limegreentj]

just zip tie it to the cage...lol its ghetto but it works

[mbg]

i was thinkin, and it may be overkill, but what do you think about adding a couple of gussets in to tie the overhead spreaders to the center windshield bar?



The cage looks sweet, I got to check it out this past weekend. Good work Justin and Jeff. I think the gussets on the center bar would look good. Save the specs on the cage I may be interested in one. Not sure when but some day.

Jeff does the center bar obstruct your view a lot when you drive on the road?

[tjblair]

No more than my spare tire does. But you could easily do the cage without the center windshield bar. In infact when Justin bent up the cage it wasn't in the plans. I just added it after. I wasn't that worried about it blocking my view because it doesn't see much street driving.

[justin'sbig7]

The cage looks sweet, I got to check it out this past weekend. Good work Justin and Jeff. I think the gussets on the center bar would look good. Save the specs on the cage I may be interested in one. Not sure when but some day.

Jeff does the center bar obstruct your view a lot when you drive on the road?


i have all the specs written down to make it all again, so its just a matter of when.

[CESCO]

I like it! And since thr rear view mirror fell of the windshield last week end then I don't have to worry about the gussets blocking the view any more than it already was. I have to firure a way th attach the rear view mirror to the cage. Also that will give me somthing to test out the new tubeshark we got today. Well the notcher anyway.

that's cool that you guys got a bender. what all sizes will you be able to bend? got any projects already lined up to use it on