Sport Bar modification

[Hedgehog]

I'm aware about what SS is all about. It always surprise me to hear folks talk about the seemingly magical wonders off SS. I'm not at all sure about hardness of SS, but these aren't your usual Dime store SS allen head bolts, they are industrial hard. I need to hit Copper State Nut and Bolt to see if they have some #8 quality hardware that looks a little nicer that a big ol' regular hex head. If not, no big deal regular hex heads it is. I'm not in a great big rush to make the pillar, but I said I was going to do it, so I will and I can see the value in it. And yes, or is that no, I don't plan on being upside down any time soon. I hear that one of the big problems with having an accident in a CJ is the strength or lack there of, of the windshield. It will bend back and make for a very bad day for those in the front seat. I believe this bar/cage is far better than nothing. With the horrible quality of the welds it originally had I'm sure its better than the horrible bar/cage it had when it arrived in my drive way. I'm glad all that was cutoff and ground smooth. The top tube was directly over my head, I bashed my melon on it regularly. This one has plenty of space over the head. I like it more every time I drive it.

 

[007]

Well whatever you do, you've done well so far. I like it.


Sent from my iPad using Tapatalk

 

[Shifter]

I like your sport bar also..

I was just poking fun due to the ones having a fit about your 1/4" setup bolts..

 

[Hedgehog]

I knew you were having fun, I even like it when people are comfortable enough to pick on me and others without fear of retribution. It shows a mature understanding even a real friendship of internet sorts.

I knew someone would mention the rather small stock dash bolts holding a Bar/cage to the front of a jeep. Honestly, I was surprised at how well they held up to the pressure and weight of the front hoop. Even when the hoop moved a little from the welds during fabrication. You would think something with no pressure on the fittings would move during welding. Not so, welding moves metal. Drilling the holes allowed an opportunity to relieve some of that pressure.

 

[Lumpy Grits]

The main reason to add the doubler plate behind the dash is to reduce the chance of stress cracks(road vibration)on the thin sheet metal.
The fasteners I wasn't to worried about-It's WHAT they were bolted to that was my concern.
BTW-When you survive two roll overs and a few times on your side. You tend to build the cage to NASCAR standards-
Remember that Jeeps get hit on the street too
LG

 

[Woolyworm]

Looks great and it adds a whole bunch of functionality. I'm in the planning phase of something similar and like the idea of the raised side and center bars since I'm 6'6" and spend a fair amount of time on the trail trying not to bang my head of the YJ ones I have in my Jeep now. Nice work HH. What size tube is that?


Wooly

 

[Woolyworm]

For others thinking about the stanchion mount there is a guy on eBay that sells the cut parts to weld up for $35. That's what I've got and plan to reinforce like HH does.

Wooly

 

[Lumpy Grits]

Wooly-Do those bolt to the dash?
LG

 

[Woolyworm]

Yup.

Wooly

 

[Lumpy Grits]

Yup-kinda what I thought.
Do you have any concern about the edges that are facing you?
Like how they include the w'shield frame for more anchor points
LG

 

[Hedgehog]

Hmmmm interesting. Mine was made intentionally so the windshield could be fully functional, you never know when it might be necessary to lay the windshield down. It wa also made with an eye toward having as many eased edges as possible, no sharp corners. Where mine is located there is no problem with whacking your knee on the thing. I suppose in a 100 MPH rollover you never know what you are going to be flopping around. But hey, I've only got a lap belt so being able to control a crash situation is almost a joke in itself.

Disclaimer: For those that are so inclined, I do not want to start another pissing contest over Pipe VS Tubing. I have a pipe bender not a tubing bender. Personally I have thought out all the other considerations and I'm happy with the answers I got.

Pipe sizes - I used schedule 40 pipe, 1 3/4" fro the rear and 1 1/4" for the front. I did learn some from the experience. One being that pipe sizes don't make any sense at all. The 1 3/4" pipe has an OD of almost 2". The 1 1/4" pipe has an OD of almost 1 3/4". None of the ID's were close to either size given. The wall thickness is far thicker than similar sized tubing

 

[Lumpy Grits]

HH-I have seen many 'pipe' cages in CJ's. The one I saw after a flop-Held up just fine.
LG

 

[Hedgehog]

Yeah, but lets not open or re-open that particular can of worms. I'm happy and comfortable with the metal I used. I understand others have very loud opinions on the matter.

 

[Woolyworm]

Thanks HH. Yes your design is slick. The top two bolts come out to drop the windshield - I also want that option. With the WS down they still have four bolts in them. Like you I not so much building a cage as I am an accessory.

LG - no I'm not concerned about the edges. To high to hit getting in or out. In a crash condition in in a 40 year old vehicle with a metal dash and no safety systems to speak of - I already moved beyond that as a concern


Wooly

 

[Petescj]

Hedge , Nice work. Glad to see the pics. Love the look from the front. Any plans on putting a cross bar in the rear or did you need it open for what you carry?

 

[Lumpy Grits]

Thanks HH. Yes your design is slick. The top two bolts come out to drop the windshield - I also want that option. With the WS down they still have four bolts in them. Like you I not so much building a cage as I am an accessory.

LG - no I'm not concerned about the edges. To high to hit getting in or out. In a crash condition in in a 40 year old vehicle with a metal dash and no safety systems to speak of - I already moved beyond that as a concern


Wooly

Really would like to see the finished job.
LG

 

[Neuner]

Very cool. Of course, now I want one.

Nice to see larger pics of your CJ. I like the green paint color. The little avatar photo doesn't do it justice.

 

[IOPort51]

For others thinking about the stanchion mount there is a guy on eBay that sells the cut parts to weld up for $35. That's what I've got and plan to reinforce like HH does.

Wooly

I decided it was easier to put the windshield angle on the dash brackets than on the end or the tube. but these are the ones mentioned above and they worked with a bit of tuning. I think that the bolts on a CJ dash may not be as "standard" as we may like to think and I had to do a bit of trimming for the glove box door. The hole for the aw shoot bar are not on the same level but I did not use it anyway.

 

[Lumpy Grits]

Those pre-cut parts for $35.00, is a bargain.
LG

 

[IOPort51]

Those pre-cut parts for $35.00, is a bargain.
LG

I agree