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View Full Version : The Bronco gets a New Cage - IT'S DONE!



Steve
February 5th, 2006, 01:53 PM
The EB is getting a new cage. I was going to have it done, but thanks to Lee (HUGE thanks!) for the loan of the bender, I'm going to do it myself. The cage will be made of .120 wall DOM; 1.75" for the main hoops & pillars and 1.5" for the rest, including the seat mounts as they'll be mounted to the cage.

I'll post pics here of the progress with lots more in my gallery; here's the beginning yesterday:

With the old cage still in:

http://www.colorado4x4.org/gallery/files/1/3/1/1/Leftsidewitholdcage.JPG


With no cage - looks funny... :P

http://www.colorado4x4.org/gallery/files/1/3/1/1/Broncowithoutcage.JPG


The old cage removed

http://www.colorado4x4.org/gallery/files/1/3/1/1/Oldcage4.JPG

Steve
February 5th, 2006, 01:58 PM
And here are the tools for the project:

JD Model 3 bender, with several dies. (A couple of welders and air compressor are in the background.) It's hydraulic/air powered. :D

http://www.colorado4x4.org/gallery/files/1/3/1/1/Bender.JPG


Notcher: (thanks to Lee again)

http://www.colorado4x4.org/gallery/files/1/3/1/1/Notcher.JPG


And the new chop saw (I had to get one new tool :D )

http://www.colorado4x4.org/gallery/files/1/3/1/1/Chopsaw.JPG

robert0913
February 5th, 2006, 02:15 PM
Nice sure would like one for my 73

Clod Hopper
February 5th, 2006, 03:20 PM
Notcher: (thanks to Lee again)

http://www.colorado4x4.org/gallery/files/1/3/1/1/Notcher.JPG


What brand notcher is this?

Steve
February 5th, 2006, 03:56 PM
What brand notcher is this?
Dunno Chip. Just went out and looked, and I can't find any brand name anywhere on it. :confused:

Cresso
February 5th, 2006, 04:17 PM
Looks like a JD2 TN-100 (http://www.vansantent.com/tube_notcher.htm) although I suppose there's a few that look very similar. It's definitely not the cheapy Harbor Freight one.

Mack
February 5th, 2006, 05:29 PM
God I love your bronco, Can't wait to see how this new cage turns out!!!

Mr. Gutwrench
February 5th, 2006, 08:07 PM
What brand notcher is this?

http://www.mtechsupply.com/view_page.php3?getcategory=Tube+Notchers&prodid=7

Steve
February 6th, 2006, 08:21 AM
Thanks for chiming in Lee. :thumbsup: When are you going to post a thread with pics of your buggy nearing completion?

abromer
February 6th, 2006, 09:59 AM
Hey, what are you going to do with your old cage?

Steve
February 6th, 2006, 10:14 AM
Hey, what are you going to do with your old cage?
You have a PM.

Wally
February 6th, 2006, 10:59 AM
Looks good steve, looking forward to some updated pics :thumbsup:

Mr. Gutwrench
February 6th, 2006, 01:28 PM
Thanks for chiming in Lee. :thumbsup: When are you going to post a thread with pics of your buggy nearing completion?

Good looking Bronco Steve. It will be fun watching what you bend up.

Haven't thought about posting pics. Just trying to get it done. Come to think about it with all the junk stacked around it I don't know if I could get a decent shot :o Thanks for getting the bender out of my way!

mtn WJ
February 6th, 2006, 07:06 PM
Yep looks great. Always had a soft spot for EBs.

Saw a Green one yesterday on a trailer that looked pretty sweet. It was being pulled by a Dodge Ram with a camper on it if anyone knows the guy.

Jocko
February 7th, 2006, 01:04 PM
http://www.colorado4x4.org/gallery/files/1/3/1/1/Bender.JPG

:drool: :drool: :drool: :drool: :drool:

Greg@RME
February 7th, 2006, 08:41 PM
Looks like a good time Steve! I love bendin' & weldin'! :cool:

Ben Holloway
February 8th, 2006, 12:40 AM
wheres the updates?

Ben

josh
February 8th, 2006, 01:35 AM
wheres the updates?

Ben

steve is sloooooooowwwww

Steve
February 8th, 2006, 09:29 AM
wheres the updates?

Ben
Buyin' the tube Friday, start bending Saturday.

Clod Hopper
February 8th, 2006, 06:33 PM
Is there any benefit to air/hydraulic setups vs electric pump for setting up a hydro ram? I have beaucoup air currently, but my looking around suggests it is the same cost to do either one.

Ben Holloway
February 10th, 2006, 03:56 PM
Is there any benefit to air/hydraulic setups vs electric pump for setting up a hydro ram? I have beaucoup air currently, but my looking around suggests it is the same cost to do either one.

From my expieriance the air over is a little slower and there is no return on it, the slow part is good if your new to bending, but it gets old pushing the ram back in all the time. The one my friend has is setup on an old log splitter modded a little with an electric motor and such, it bends quick and comes back in with a switch of a lever. a little scary though if you have never used it before

Ben

Steve
February 10th, 2006, 05:54 PM
Hooked up the trailer and bought tube today!!! :bounce4: 2 sticks of 1.75" .120 wall DOM, 2 sticks of 1.5" .120 wall HREW and 1 stick of 1.25" .120 wall HREW, plus 12 precut pieces of .25" plate, all for $310. I was expecting it to be a lot more expensive.

The B hoop, A pillars to connect to B hoop, from B hoop to rear of bed and spreaders above the seats will be 1.75" DOM. Cross bracing will be 1.5" HREW, and seat mounts will be 1.25" HREW.

Gonna attempt tube bending tomorrow. :D

Explorerguy
February 10th, 2006, 07:37 PM
Hooked up the trailer and bought tube today!!! 2 sticks of 1.5" .120 wall HREW
Gonna attempt tube bending tomorrow. :D
I know where there is a nice looking Sami that could use those 2 sticks of HREW.... :D GOOD LUCK!!!

cheepin
February 10th, 2006, 07:46 PM
Who did you get your tubing from.Bonner?

Steve
February 10th, 2006, 08:11 PM
Who did you get your tubing from.Bonner?
Yep.

Mack
February 10th, 2006, 09:55 PM
What's that DOM going for now per foot?

Steve
February 10th, 2006, 10:09 PM
What's that DOM going for now per foot?
I paid $3.95/ft for 1.75" .120 wall DOM. I thought that was pretty good.

2LoudDodge
February 10th, 2006, 10:25 PM
where is Bonner at?

Steve
February 10th, 2006, 11:28 PM
where is Bonner at?
Grand Junction. :P

2LoudDodge
February 10th, 2006, 11:31 PM
eeeek. Cost me more in cash to go there then what I'd prolly save. LOL

Mack
February 11th, 2006, 03:20 PM
Steve-
Thanks. I've got 6-8 sticks of the stuff i'm storing because plans changed and I have no use for it, so trying to figure a ballpark $ amount to put it on the board for.

Steve
February 11th, 2006, 03:33 PM
UPDATE (such as it is...) Got the bender all set up with a brandy new 1.75" die. While making the first bend, the die broke! :eek: Fortunately, Lee was here at the controls showing me how to make the first bend. The part that's welded onto the die to attach the U strap to broke off the die. From looking at it the welds were crap and had NO penetration into the die at all. So, Lee's gotta order a replacement die before I can do anything more. :(

Scorpion
February 11th, 2006, 09:49 PM
UPDATE (such as it is...) Got the bender all set up with a brandy new 1.75" die. While making the first bend, the die broke! :eek: Fortunately, Lee was here at the controls showing me how to make the first bend. The part that's welded onto the die to attach the U strap to broke off the die. From looking at it the welds were crap and had NO penetration into the die at all. So, Lee's gotta order a replacement die before I can do anything more. :(

I'd just clean it up and burn the damn thing home so you could get back to bending. Get 'er done!! ;)

Steve
February 11th, 2006, 09:53 PM
I'd just clean it up and burn the damn thing home so you could get back to bending. Get 'er done!! ;)
Trust me, we seriously considered doing just that. Lee just got the die a couple of days ago though, and this was the first bend with it. Due to that, we decided that it's better to call them first thing Monday morning and get another one shipped this direction.

Ben Holloway
February 11th, 2006, 10:59 PM
Trust me, we seriously considered doing just that. Lee just got the die a couple of days ago though, and this was the first bend with it. Due to that, we decided that it's better to call them first thing Monday morning and get another one shipped this direction.

the next one they send you might be garbage too, we had that happen to us on 2 dies, we welded them back together and havnt had a problem since

Ben

Mr. Gutwrench
February 12th, 2006, 01:00 PM
the next one they send you might be garbage too, we had that happen to us on 2 dies, we welded them back together and havnt had a problem since

Ben

What kind of bender?

Ben Holloway
February 13th, 2006, 09:05 PM
its a pro-tools 105 HD, we had it happned on a 1.75 die and a pipe die, i think it has to to with the fact that its cast, the placement isnt super critical so we just stuck it back where is looked right cranked up the 250 and burned it back together. no problems to date and weve done quite a bit of bending

Ben

Mr. Gutwrench
February 14th, 2006, 01:48 PM
Thanks Ben. I was curious if the problem was unique to JD.

My first impulse was to send it back and let them stand behind their high priced junk:mad: but to save time and hassle I'll weld it myself. Another problem was the pin that goes through the "U" and the broken part didn't, so when the part is welded back it can be positioned so the pin will go through.

No complaints concerning the vendor I bought the die from. They were ready to pay for shipping and take care of the problem. It just seems easier to take care of it myself.

Ben Holloway
February 14th, 2006, 10:10 PM
Thanks Ben. I was curious if the problem was unique to JD.

My first impulse was to send it back and let them stand behind their high priced junk:mad: but to save time and hassle I'll weld it myself. Another problem was the pin that goes through the "U" and the broken part didn't, so when the part is welded back it can be positioned so the pin will go through.

No complaints concerning the vendor I bought the die from. They were ready to pay for shipping and take care of the problem. It just seems easier to take care of it myself.

I think both benders are a wash, I like the pro-tools bender but the JD's dies are nice(well parts of them) like the replacable shoes, our pro-tool dies have to be cleaned up almost before every use

Ben

Steve
February 18th, 2006, 06:33 PM
Got the die fixed, and made progress today. Tube bending is fun!!! :D


Bending the B Pillar Hoop:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0505.JPG


B Hoop mocked up:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0507.JPG


Rear braces mocked up:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0508.JPG


Today's progress:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0509.JPG

2LoudDodge
February 18th, 2006, 06:35 PM
nice. Keep them pics comin!

Ghettojeep
February 18th, 2006, 06:47 PM
needs more triangulation. :flipoff2:


sorry.... had..... to.... :D

Steve
February 18th, 2006, 07:22 PM
needs more triangulation. :flipoff2:

It's coming. :flipoff2:

:beer:

Clod Hopper
February 18th, 2006, 08:54 PM
Steve, is your bronc perpetually topless or are you setting up the cage to still accept a top?

Also, why is your star extra big? Because you are a moderator or just cause you are an "elitist"? :flipoff2:

jimminyC
February 18th, 2006, 09:05 PM
looks great Steve! Maybe Lee will have his buggy finished by the time you get your cage done! I have officially named it the Bronco Buggy since its all Bronco colors. But i must say, Both the team and the buggy have been about equally successful at running this year. (kidding Lee) :)

Steve
February 19th, 2006, 10:36 AM
Steve, is your bronc perpetually topless or are you setting up the cage to still accept a top?
Except for the trip to Moab over New Year's weekend when I put the full soft top on, it's only had a bikini top for the past several years. I am making the cage so that the full soft top will fit on it.

Mr. Gutwrench
February 20th, 2006, 06:18 PM
Looks good Steve. I'm impressed. It looks so good in fact I think you ought to consider cutting the back half off and tubing it out :D

Mr. Gutwrench
February 20th, 2006, 06:34 PM
looks great Steve! Maybe Lee will have his buggy finished by the time you get your cage done! I have officially named it the Bronco Buggy since its all Bronco colors. But i must say, Both the team and the buggy have been about equally successful at running this year. (kidding Lee) :)

Don't know how the buggy came out orange. I used Steve's paint gun and the paint I mixed and poured into it was green, but it came out orange :eek:

Steve
March 4th, 2006, 07:36 PM
After lots of business travel, finally got to work on it again. Still need to fab the mounts for the new seats and add more triangulation and gusseting - tomorrow. Progress as of today:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0512.JPG

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0513.JPG

Mr. Gutwrench
March 5th, 2006, 09:26 AM
Good job Steve. It took some planning to get those A pillars right. How do you like bending by now?

Steve
March 5th, 2006, 07:56 PM
Good job Steve. It took some planning to get those A pillars right. How do you like bending by now?
Yeah, the A pillars were a PITA. The seat mounts turned out to be more work than I thought they'd be. Bending is fun! :D Here are a few pics after working on it all day:


From the front:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0514.JPG


From the sides:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0518.JPG

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0517.JPG

Still has some work to be done, but most of the fab work is complete. Hopefully have it complete, painted and installed by the end of next weekend. :D

cojeepster
March 5th, 2006, 08:34 PM
Wo,


Looks Awesome! Great job... You will be building full tube chasis before you know it!

Wally
March 6th, 2006, 02:45 PM
Does this mean you'll actually take the hard lines since your cage will finally stand up to a rolling :flipoff2:

Steve
March 11th, 2006, 10:02 PM
All fab work and welding is done. Just gotta clean it up, paint it and install it.

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0520.JPG


http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0523.JPG


There's about 100' of tubing in it. :eek:

2LoudDodge
March 11th, 2006, 10:03 PM
looks., good. nice lookin seats too.

Mike Boyle
March 11th, 2006, 10:57 PM
Nice work Steve.

Mr. Gutwrench
March 13th, 2006, 09:26 AM
That is nice work.

74BuckinBronc
March 13th, 2006, 10:11 AM
There it is! Looks great! Hard to believe that there is THAT much tubing, but I have never built one myself, so I wouldn't know. Can't wait to see that installed pic!

J.D.

Steven_Mc
March 13th, 2006, 11:21 AM
Looks good, but where are the pics of it mounted in the Bronco?? :shrug:

josh
March 13th, 2006, 02:07 PM
looks good steve.

I really need to get a bender. not sure if I have the patience to measure enough to ever get my bends right though

Steve
March 13th, 2006, 02:57 PM
Looks good, but where are the pics of it mounted in the Bronco?? :shrug:
I was debating whether to paint it or powder coat it. After a call this morning to a local powder coater, it goes to them later this week. I was very pleasantly surprised how cheap it is. It will be installed the middle of next week; I'll post the last pics then.


I really need to get a bender. not sure if I have the patience to measure enough to ever get my bends right though.
It's actually a lot easier to do than you'd think Josh. I only did one bend wrong and that was one of the first couple I did. The Tube Bending 101 file on PBB - complete with pics - was a HUGE help in figuring out how to measure and bend correctly. Lee was also a huge help since it's his bender and he'd probably done 10,000 bends with it just for his buggy alone. :D

Ben Holloway
March 13th, 2006, 10:23 PM
I was debating whether to paint it or powder coat it. After a call this morning to a local powder coater, it goes to them later this week. I was very pleasantly surprised how cheap it is. It will be installed the middle of next week; I'll post the last pics then.

whats the name of the shop steve, we are looking for a good production coater, got any good references or people we should stay away from?. Oh and the cage looks pretty killer. One last thing what year of civic did you get the seats out of:flipoff2:

thanks
Ben

Steve
March 14th, 2006, 09:03 AM
whats the name of the shop steve, we are looking for a good production coater, got any good references or people we should stay away from?.
Pro Powder Coating here in town.


Oh and the cage looks pretty killer. One last thing what year of civic did you get the seats out of:flipoff2:

thanks
Ben
Actually I bought those seats, never installed, from a board member here last year. Been waiting to install them until the cage is done. :P

Kirby N.
March 18th, 2006, 10:54 PM
Hows about throwing a cage togetherfor my rig!

Looks rad! Cool Bronco too!

Steve
March 26th, 2006, 05:37 PM
Got it back from Pro Powder Coating on Thursday, they did a great job coating it hammered black. Here are some pics of the completed cage installed in the Bronco. Time to go wheeling! :)


http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0536.JPG


http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0537.JPG


http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0539.JPG


New seats & harnesses, all connected to the cage:

http://www.colorado4x4.org/gallery/files/1/3/1/1/IMG_0538.JPG

cracker_1
March 26th, 2006, 06:39 PM
Damn, looks really good Steve! Can hardly wait for the Bronco Safari, so I can see it in person and a few more EB's... I got tagged to run the OHV Rock Crawl Expo on Sunday, instead of Sat. So, we will be in Denver on Sunday, April 9th instead. ttyl...

Cresso
March 26th, 2006, 06:59 PM
Cool! Post pics of testing it. :evil:

YJgirl
March 27th, 2006, 10:01 AM
NICE STEVE!!!! :thumbsup: :thumbsup:
wanna go test it this weekend??? :evil:

Steve
March 27th, 2006, 10:07 AM
Cool! Post pics of testing it. :evil:
Just because I have a new cage doesn't mean I'm going to start driving like Wally. :stirpot:


NICE STEVE!!!!
wanna go test it this weekend???
:D

Alpine Spirit
March 27th, 2006, 12:09 PM
That thing is awesome!!!! Nice job.

87xjco
March 27th, 2006, 12:43 PM
Looks killer, nice job!!

Jeffro600
March 27th, 2006, 02:42 PM
Looks great, but a question for ya....it looks somewhat similar to the original one you had in there....why the change??

Steve
March 27th, 2006, 03:22 PM
Looks great, but a question for ya....it looks somewhat similar to the original one you had in there....why the change??
Couple of reasons. The A pillars on the old one were straight and were in the way; I bent the new ones to follow the dash and windshield to be as out of the way as possible. Second, I wanted one with bracing (gussets), triangulation and bars over my head, as well as the seats and harnesses mounted to the cage instead of the body, none of which the old cage had. I could have added all of that to the old cage, but it would have been just as time consuming and almost as expensive as building the new one from scratch.

Plus, bending tube is fun! :D

Wally
March 27th, 2006, 04:06 PM
Damn Steve, that looks GREAT, can't wait to get out and wheel with ya, i'd be happy to give you some driving tips so you can FULLY test it out :flipoff2:

MikeEB
March 27th, 2006, 04:37 PM
Looks damn good man. Gonna, have to get over to GJ one of these days and check that thing out, still impressed with the narrowing job.

Mike

89minitruck
March 27th, 2006, 10:57 PM
I'm not sure how I feel about parking my dented up rig next to that... That is WAAAY purdy. It's almost too purdy to wheel... let's dent it up alittle. Where's my hammer?

Seriously, you did an awesome job with the cage. Maybe I can get you to pull out some of dents...

aj

Steve
March 28th, 2006, 10:37 AM
I'm not sure how I feel about parking my dented up rig next to that... That is WAAAY purdy. It's almost too purdy to wheel... let's dent it up alittle. Where's my hammer?
Haven't seen the other side of it have you? :P Every 3 or 4 years I straighten and paint it and then wheel it hard. It's been 3 years since I did that...

I'm very happy with the way the cage turned out considering it was my first time bending tube. :D

josh
March 28th, 2006, 03:11 PM
Every 3 or 4 years I straighten and paint it and then wheel it hard. It's been 3 years since I did that...


2 years

looks awesome steve. The seats look comfy

Steve
March 28th, 2006, 04:53 PM
2 years

looks awesome steve. The seats look comfy

Only 2? Damn Alzheimers. :(

Yeah, the seats & harnesses are much better than the old ones. Let's go wheeling! :thumbsup:

josh
March 28th, 2006, 04:54 PM
Only 2? Damn Alzheimers. :(

Yeah, the seats & harnesses are much better than the old ones. Let's go wheeling! :thumbsup:

I'll ride with you I dont think my rig will ever be done

Mr. Gutwrench
March 28th, 2006, 08:12 PM
I dont think my rig will ever be done

I know the feeling. Cage looks good. Powder coating is the way to go, heh?

MyCJ4Rox
March 30th, 2006, 10:12 AM
Looks great Steve. BTW, Happy Birthday-Patrick, Ron and Jeff at BSI

89minitruck
April 1st, 2006, 09:02 PM
I'm impressed for your first time bending... of course, you strike me as a very patient guy, which is good. Not the typical for a wheeler... :D

lwg
April 20th, 2006, 10:29 PM
Just curious if you tied it into the frame? And how you did it if you did?

Steve
April 21st, 2006, 08:52 AM
Just curious if you tied it into the frame? And how you did it if you did?
Yes, it's tied into the frame with these. (http://www.polyperformance.com/shop/product.php?productid=433&cat=105&page=1)

crackhead
May 13th, 2006, 01:52 PM
Hate to dig up an old thread, but you cage looks really good.. Couple of questions.. About those frame tie ins.. Do you weld the round part with the bushing in it to the frame support and then bolt it together and sandwich the tub w/ it? (is that too confusing?) Also, do you have a better pic of how you mounted your harnesses?? Thanks..

Brian

EEJEEP
May 13th, 2006, 10:35 PM
Hate to dig up an old thread, but you cage looks really good.. Couple of questions.. About those feame tie ins.. Do you weld the round part with the bushing in it to the frame support and then bolt it together and sandwich the tub w/ it? (is that too confusing?) Also, do you have a better pic of how you mounted your harnesses?? Thanks..

Brian

X2

Also, how are you liking the harnesses. I recently just bought some RCI. Any tips on installing them?

Steve
May 13th, 2006, 10:48 PM
Brian, that's exactly how the frame tie-ins mount. I'll get some more pics and post them, including of the harness mounting, later next week when I get back in town.