Roll Bar Project |
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Posted: 16 Feb. 2019 at 1:38am |
This is something Ive been wanting to do for awhile. After talking with Jpet last year I decided to go for it. FYI Im not taking credit for this design. Jpet told me about his idea and I "borrowed" his 3D drawing from one of his threads.
The plan is to build a roll bar that follows a similar shape to the factory 2a bows. I want my canvas top to fit and the bar to not look super obvious. I love the simple old 2a look.... So I wanted to avoid a big full cage. This is the Image from Jpets thread. Jeff Was kind enough to stop by the other night and let me borrow his bender. It was fun and helpful to chat about roll cages, jeeps, etc.... THANKS Jeff! Bender... Since this was used on BAM BAM maybe it will give my jeep some special powers! Right now Im in the Prep phase. I Have the bender....Material is ordered. Now im working on building a tubing notcher. The harbor frieght one looks like a piece of junk and a good one is out of my price range. So I started building one out of stuff I had laying around. The angle will be adjustable. Right now its centered only for 1.5" tubing. If I have another project in the future I will have to make adjustments. Edited by Millennium falcon - 16 Feb. 2019 at 1:48am |
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Its been a few days and my material is here.
I always love my trip to the metal shop.... they have cool stuff laying around. I have 56 feet of 1.5" .120 wall DOM tubing. I also Got some 1/4" angle for the tub mount and 1/4" plate for the frame tie in points. So thats where im at for now... I think imp going to adapt my hole saw arbor directly to the shaft so I will be working on that and starting to bend tube this weekend. I have another video made. I will post it once its on youtube. Updates to come!
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11173 |
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I'm looking forward to this project
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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ndnchf
Member Sponsor Member x 2 Joined: 22 Sep. 2017 Location: Virginia Status: Offline Points: 2177 |
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I love seeing the machine work. Great fun.
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1948 CJ2A - It goes nowhere fast, but anywhere slow.
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smfulle
Member Sponsor Member Joined: 16 Sep. 2010 Location: Ogden, Utah Status: Offline Points: 6123 |
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Seth, the metal magician.
Next project, a Flux Capacitor out of junk he had just laying around in the shop.
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LuzonRed47
Member Joined: 11 Apr. 2007 Location: Plymouth, MI Status: Offline Points: 841 |
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Falcon, it's hard to tell from the CAD illustration whether this roll-cage system will be attached to the jeep's frame rails (for optimum strength) or simply bolted to the body. We've all seen roll cages bolted to the 16-ga. sheet of the jeep's upper wheelhouses where the cage's integrity (and the occupant's safety) depends on the shear strength of whatever fasteners are used--not a good thing in a severe roll-over. At what points does this configuration fasten to the frame?
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CJ2A #140275 "Ziggie" (purchased new by my dad in 1947)
ACM #124334 CJ3A windshield, Warn Overdrive 1953 Strick M100 trailer Serial #18253 |
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Willys Jeep Junkie
Member Joined: 09 Nov. 2017 Location: Auburn Hills Mi Status: Offline Points: 3 |
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Nice work Seth, Looking forward to seeing more progress. Thumbs Up.
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Thanks guys, I hope to make progress on this soon. Luzon: yes it will be tied into the frame In 4 places. The pictures above shows the “frame attachment plates”
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Ready to begin!
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jpet
Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11173 |
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Good work! This is a fun thread!!
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CJ2A #29110 "General Willys"
MB #204827 "BAM BAM" "We do what we can, and we try what we can't" |
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bobevans
Member Joined: 31 July 2005 Location: Pittsburgh, PA Status: Offline Points: 844 |
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Very nice. I just watched the Eastwood notcher video, but don't want to spend $400. Wish I had your fab skills!
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'48 CJ2A
'56 DJ3A '79 CJ7 And two of them actually run! |
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Thank you Bob! I have learned a lot of what I know from watching you guys on this forum. I totally agree with you on the Eastwood notcher. Looks nice....its just too expensive. No one seems to have a "middle of the road" option. They are either cheap junk or pro quality and very expensive. Eastwood has a $99 notcher but it looks cheap and the reviews say its basically the harbor freight notcher painted blue.
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Well, I finally made some progress....
It was cold in the shop today. My toes were cold and I ran out of time. Hopefully I will get more done tomorrow. There is a learning curve to this....Progress should go faster now.
Edited by Millennium falcon - 20 Feb. 2019 at 5:26am |
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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Today I got the other bow sorted out.
I'm quickly learning this is not a fun one man job... holding everything straight...working the press, lifting things in and out to test fit....measure, make marks... would all be easier with an extra set of hands... I had to get creative today. Now im trying to figure out how I want to mount the bars to the tub. I bough angle iron and plates but the ribs on the tub cause issues.. |
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Mark W.
Member Sponsor Member Joined: 09 Nov. 2014 Location: Silverton, OR Status: Offline Points: 7923 |
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My dad placed good quality 3/4" plywood routed out for the ribs under his roll bar but it was mounted on a full plate that covered the whole top of the Wheel house. I did much the same with mine but used Micrata and then used Micarta to trim around the edges of the 1/4" boiler plate I used for the base.
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Chug A Lug
1948 2A Body Customized 1949 3A W/S 1957 CJ5 Frame Modified Late 50's 134L 9.25"clutch T90A D18 (1.25") D44/30 flanged E-Locker D25 5.38 Since 1962 |
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Millennium falcon
Member Joined: 20 Sep. 2016 Location: Central PA Status: Offline Points: 1521 |
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maybe I will just let it land where it wants and then when I clamp it to the frame tie points it will flatten out..
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athawk11
Member Joined: 18 Jan. 2012 Location: Arvada,Colorado Status: Offline Points: 4145 |
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At some point, you may regret crushing the ribs. Why not trim the angle to fit? Or add a spacer beneath the angle?
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1- 1946 CJ2A
2- 1949 CJ3A |
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Mike F
Member Joined: 12 Aug. 2018 Location: Longview wa Status: Offline Points: 684 |
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I would get some sheet HDPE. Should be able to get it in the right thickness won’t hold water easy to mill out to fit. Cant break it.
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