Phase 4 - Rollcage inside the cab

[klaus]

Before the project actually started I was under the impression that building the rollcage is simply one phase by itself independed from all other components of the truck. Quick did I learn that all aspecs of the vehicle tie into each other. The tubing behind the cab connects into the cab at multiple points and close attention must be taken right away on the cab cage design.

Since the new SCORE rules ask for 2" tubing for all trucks over 4000lbs the project Ranger uses 2" 4130 tubing for all its main roll-cage structure. It may seen overbuild but thats what the rules call for and even though I plan not to race the truck anytime soon it would be a disapointment down the road if I would want to enter it in a SCORE event but couldn't pass tech.

All welding is done by MIG rather then TIG in order to save time and for simplicity reasons.

[klaus]

Picture of the first 3 tubes of the cage.
This will connect close to the rear shock mounts behind the cab.

The horizontal tube is set some further back then the b-pilar of the vehicle allowing for more legroom and relaxed seat position. This horizontal bar will be the mount for the shoulder portion of the 5-point seatbelts

[klaus]

Next the horizontal bar gets tied into the frame below.
We cut out large holes above the stock framrails.
These holes will be patched up with sheetmetal down the road.

[klaus]

Here a main-tube connects from the front of the cab outside frame to the rear roof.
We used three tubes per side, each one with one bend (total of three bends). Using three sections was a lot easier then making it out of one single tube. However all pieces are "roset-welded", got tagged inside the cab, then the total assembly got removed and welded permanently outside on a bench. That way we were able to weld around the entire tube and not skip those hard to get to places that are often overlooked.

Some of these tubes will be in plain view close to the windshield, so we sanded down the excesive welds to give the joints a flawless look. It doesn't fully look that way right now, but once the cage is painted it will be (hopefully) invisible.

[klaus]

pictures show more progress.

[klaus]

Pictures of the tubes connecting left to the right side.

[klaus]

Here are some more updated pictures.
The "b-pillar" roll-bar is now one piece under the roof.

[klaus]

some updated images of the current status of the cab cage.