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  1. #21
    Weekend Warrior pvanweelden's Avatar
    Join Date
    10-31-2014
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    Des Moines
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    426
    Awesome work!

  2. #22
    Yamaha90 JMG Designs LLC's Avatar
    Join Date
    11-18-2011
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    Vermilion, OH
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    3,136
    Great work so far, can't wait to see your finished product!
    Click the image above to visit our website!

    Mike
    F/R Rubicon Axles
    3.5 Rock Krawler X-Factor
    17" AE Beadlocks
    37" Nitto Trail Grapplers
    JE Reel F. Shaft 1310
    Poison Spyder Brawler Mid Front Bumper
    Poison Spyder Crusher Flares
    Poison Spyder Armor & Rocker Knockers
    JCR Offroad Crusader Rear Bumper/Carrier
    6" KC Slimlites

  3. #23
    New JK Freak
    Join Date
    01-08-2017
    Location
    Texas
    Posts
    48
    Thanks for the kind words.

    Ringer- I have considered the stock rectangle cross tube and I have decided not to replace it, but will be reinforcing it in key spots. It is .120ish wall rectangle tube, albeit bent with some holes. I think the main shortcoming is the way it attaches to the side rails.

  4. #24
    New JK Freak
    Join Date
    01-08-2017
    Location
    Texas
    Posts
    48
    Today's progress was the front two roof bars. The key here was to make sure there was no chance of head-to bar- impact while wheeling or on the street. These bars will eventually be padded with a two stage impact rated pad.

    I also wanted these to be in the same plane as the outer roof bars.

    also included are some pics of how I like to finish my tube ends.
    I sand the end to be welded so that wall thickness is full value(no paper thin edges)
    I then use the slack side of the belt to clean the mill scale off to improve weld quality.
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    Some progress pics:
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  5. #25
    New JK Freak
    Join Date
    01-08-2017
    Location
    Texas
    Posts
    48
    Update, got the rear section welded up. Next is to pull the front for welding
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    Last edited by Airwolf; 02-20-2017 at 05:03 PM.

  6. #26
    Supporting Freak Kerm-icon's Avatar
    Join Date
    07-11-2012
    Location
    Ohio
    Posts
    1,238
    Damn! Looks outstanding!
    _________________________________________________
    Gecko 2013 JK
    Crawler Conceptz Stinger | ACE Sliders | DayStar Leveling Kit | 35" Goodyear MTR/Ks | ProComp 7069s
    XRC Flat Fenders | Smittybilt Roof Rack | HID Projector Headlights | 3x 20" LED Bars

  7. #27
    Driving his wife's Jeep
    Ringer's Avatar
    Join Date
    01-19-2012
    Location
    Chardon, OH
    Posts
    3,706
    Looks great. What are your plans for tying into the frame or are you just planning on leaving it welded to the body?
    RubiXcon
    No matter what you have, there is ALWAYS a better way to do it.
    My build thread- https://www.jkfreaks.com/forums/showt...ld-up-of-JKarl

  8. #28
    New JK Freak
    Join Date
    01-08-2017
    Location
    Texas
    Posts
    48
    There will be a oversized corresponding plate on the bottom side of the floor at each leg of the cage with through bolts to tie them together.

    I think even a bushing style frame tie in would be to ridges for this daily driver.

  9. #29
    New JK Freak
    Join Date
    01-08-2017
    Location
    Texas
    Posts
    48
    Just More Welding Today, but I thought I would post a tip that I am sometimes reminded of the hard way

    When welding a captured tube (especially with TIG) the hot gas inside the tube will build pressure as you apply heat and it needs somewhere to go. Sometimes as you are just finishing welding the circumference of a tube closed, the hot gas will caused the weld pool to "pop" out and leave you with a nasty blow out that cannot be filled until everything cools off.

    The solution to this is to drill a small vent hole, preferably somewhere that will be covered by an intersecting tube so the hot gas can escape while you weld.
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  10. #30
    Freak of Knowledge ShutterBug's Avatar
    Join Date
    09-08-2013
    Location
    Mentor, OH
    Posts
    2,792
    I'm just getting into welding, learning more all the time. Although I don't see a custom cage in my near future, this is still a great tip. Thanks!

    Cage looks awesome. Can't wait to see how it all looks when you have the trim and everything buttoned up. I hope you took good measurements and plans, you could sell kits.
    2014 Black JK Sport-icon - My "Lil' Mule"
    JCR Offroad | Rock Krawler | Barnes 4WD | Artec | RCV | Ten Factory
    My Build Progress

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