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-   -   Interior Roll Cage Design (http://www.fordrangerforum.com/fabrication-and-tool-tech/31120-interior-roll-cage-design.html)

Gumcrew2 04-12-2011 03:19 PM

Interior Roll Cage Design
 
Having some dream plans for the ranger and trying to mock up a cage for recreational use. Here's what I've got so far::

6 tubes total going parallel across the width of the truck: windshield, dash, 3 on the back of the cab (top middle bottom) and one across the front of the underside of seats.

2 tubes that match the door frame essentially: floor plate where seatbelt bottom mounts, up to top of cab, forward to windshield top, down side of dash (cutting dash required), to floor plate by kick panel.

2 parallel tubes running from the lower cab tube to the front floor plate.
2 paralel tubes going from lower cab tube to the ankle/seat tube.


I'm thinking 1.25" X 0.120" HREW. I want to keep it small tube size but strong so might go to 0.188" wall. Using .120" Wall will keep the total cage weight somewhere around 100lbs. DOM would be nice, but at $4.50/ft not cheap, where as HREW is running under $2/ft. About 65ft of tube total. So all I'd really need is the tube, some floor plates (old leaf spring plates work pretty well), and another spool of welding wire.

What's everyone's thoughts? I would maybe add some triangulation to the rectangular roof section but really don't need a ton of strength here, weight is a bigger concern. Not designing it for offroading, just to be safe if I take a corner a little tooooo fast.



http://i139.photobucket.com/albums/q...2/Interior.jpg

DiabloBlanco 04-12-2011 03:31 PM

Re: Interior Roll Cage Design
 
http://i180.photobucket.com/albums/x...2/Interior.jpg

red only. Might be illegal to have the two brs in your window. If it is take em out.

----------

also forgot the cross beam on top. Should run diagonally across

Pickupman04 04-12-2011 03:39 PM

Re: Interior Roll Cage Design
 
Triangulation is your friend!

DiabloBlanco 04-12-2011 03:41 PM

Re: Interior Roll Cage Design
 
exactly.

Gumcrew2 04-12-2011 04:07 PM

Re: Interior Roll Cage Design
 
I know triangulation is the most beneficial.

I can't do windshield bars on the front (found that one out when I chopped my Cherokees top and went full exo-cage)

On the lower half, you don't see a need for a lateral bar under the seats? I want to be able to mount 5-points in it at some point and will most likely have a crotch strap needing a lower mount. I added those parallel bars on the bottom figuring triangulation always better.

That does save tube though, I like the layout

ben10 04-12-2011 04:50 PM

Re: Interior Roll Cage Design
 
damn you CAD guys are goooood :D mounting the seats to the cage would make it a lot more safe, i say combine the 2, and yeah triangulation is key.

Gumcrew2 04-12-2011 07:26 PM

Re: Interior Roll Cage Design
 
^^ I plan on mounting the seats to the lower rear tube (from my original with 3 tubes across the back).

The previous owner mounted the seats with 4" long spreader-type DRYWALL toggle bolts and used NUTS as spacers to raise 'em up. So need less to say, there gonna get a new mount.


I like the idea of having a lateral bar across the door parallel to it for side impact. I was concerned about tucking my knees in to get in as it's a small truck already. But I'm short so it's not a big issue.

ben10 04-12-2011 07:30 PM

Re: Interior Roll Cage Design
 
honsetly the bar will only do so much in an impact, if you have a few bars protecting you, it will help, but one bar wont do all that much, this seems a bit overkill for a stock rig...

Gumcrew2 04-12-2011 07:38 PM

Re: Interior Roll Cage Design
 
Quote:

Originally Posted by ben10 (Post 388281)
honsetly the bar will only do so much in an impact, if you have a few bars protecting you, it will help, but one bar wont do all that much, this seems a bit overkill for a stock rig...

I know a single bar isn't much, but it's ALOT over the factory paper-wall rusted door.

Overkill for stock? Definitely. Considering I like to take it on little private tracks around town and take turns on 2-wheels in 3rd gear with the Miata's I think it's a reasonable safety factor. Something about having F/R THIICk sway bars makes it way to fun.

That and I'm WAY over cautious now after rolling my XJ (even with a cage, and we we're all fine). So I'd rather play it safe.

ben10 04-12-2011 07:40 PM

Re: Interior Roll Cage Design
 
oooooooh i didnt know you were on tracks and what not. in that case yeah cage for sure.

DiabloBlanco 04-12-2011 07:42 PM

Re: Interior Roll Cage Design
 
JUst do a full cage man.

doyouquaxu 04-12-2011 07:43 PM

Re: Interior Roll Cage Design
 
are you going to tie it into the frame, or just bolt it to the thin sheet metal?

Gumcrew2 04-12-2011 08:11 PM

Re: Interior Roll Cage Design
 
Quote:

Originally Posted by DiabloBlanco (Post 388299)
JUst do a full cage man.

Thought about it: want weight at a minimum, keeping the 2.3L
Doing the full cage on my XJ took almost 280ft!

Quote:

Originally Posted by doyouquaxu (Post 388300)
are you going to tie it into the frame, or just bolt it to the thin sheet metal?

It'll have floor plates that mount it through the floor to the frame (floor plates on both sides of the floor), with the underside floor plate welded to the frame.

DiabloBlanco 04-12-2011 08:14 PM

Re: Interior Roll Cage Design
 
turbo that shit then.

Gumcrew2 04-12-2011 08:18 PM

Re: Interior Roll Cage Design
 
Quote:

Originally Posted by DiabloBlanco (Post 388330)
turbo that shit then.

Sitting on the garage floor is headers, turbo, 4-barell blow through carb, and intake manifold. Still bolted together

I'm working on it :D

When I did the simple rebuild 3000mi ago I used forged rods/pistons for a reason


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