How to get this top tube right

[ccbruin]

I would like to put a tube across the top, connecting to the tube tubes on each side. Can't do that intense of angle on my notcher. The only way I can think of being able to make the side fit somewhat flushly is by using a plasma cutter. Anyone else have any ideas?

http://i843.photobucket.com/albums/zz351/ccbruin3/F7342581-13A4-49D4-BF9B-4371ED63A5C1_zpsrjdazttl.jpg (http://s843.photobucket.com/user/ccbruin3/media/F7342581-13A4-49D4-BF9B-4371ED63A5C1_zpsrjdazttl.jpg.html)

[Robert B]

i must not be exactly understanding what you are trying to do as that looks fairly straightforward and easy:confused:

[Jim]

Me too (though I would not have any knowledge to give).

Could you edit the image and draw a colored line where you're looking to have the tube route?

[Cr33p3r]

Are you trying to get it to come down in between the headlights or to the outside of the fenders? If you want bring it over and I can see what we can do with it.

[ccbruin]

like this:
http://i843.photobucket.com/albums/zz351/ccbruin3/F7342581-13A4-49D4-BF9B-4371ED63A5C1_zpsbdc46fb7.jpg (http://s843.photobucket.com/user/ccbruin3/media/F7342581-13A4-49D4-BF9B-4371ED63A5C1_zpsbdc46fb7.jpg.html)

[Serious Offroad]

This might help you get it laid out:
http://www.pirate4x4.com/articles2/tech/bendin_tube

I would think a couple 45deg. notches would do it.

Notching links.
http://metalgeek.com/static/cope.pcgi
http://www.pirate4x4.com/tech/billavista/Links/

[redneck23ms]

notch it with a grinder

[Popsgarage]

Depending on what brand of notcher you're using Troy at Swag Offroad.com sells what he calls the Reach Around. It's made for the JD2 notcher and allows the notcher to swing past it's stop. For some reason, the computer won't let me pull up Swag.


Got it.

http://www.swagoffroad.com/JD2-Notch-Master-Reach-Around_p_49.html

[Tnsejed]

notch it with a grinder

+1

[Cr33p3r]

I usually use my notcher to the max limit and then I hold the piece up to where I want it on the existing piece and mark an outline of the curve it will mate to and grind it to match closer for welding.

[Fordguy77]

You can also use a Port-A-Band to notch it out. Mark where you need the notch to be with a sharpie, lay the portaband almost flat against the pipe(to match the angle of the notch) and cut away. Its not the best method but it works fairly well. Use it alot when were notching out pipe for hand rail at work. Or as others have said have at it with a grinder.

[Dutch]

I have a Pipe Master for 1.75" OD tube, it worked great when I built the cage for my YJ

http://images.minitruckinweb.com/shop4parts/0804mt_04_z+mini_market+pipemaster_tools.jpg

[CS79bronco]

I need one of those.

[Cr33p3r]

I've been wanting to buy a set of them but a bit pricie right now for a set. They work great!

[Popsgarage]

I've been wanting to buy a set of them but a bit pricie right now for a set. They work great!

Drool worthy, for sure.

[ccbruin]

I think I am going to add gussets on each side. Then weld the top tube to them. I think It'll be easier:

http://i843.photobucket.com/albums/zz351/ccbruin3/FrontBumperGussets_zps95977c0b.jpg (http://s843.photobucket.com/user/ccbruin3/media/FrontBumperGussets_zps95977c0b.jpg.html)

[Serious Offroad]

Won't look nearly as good though (IMHO).

[Cr33p3r]

That will add some reinforcement which is always a good idea.

[Jim]

I need one of those.

An "on the cheap" I'd think would be readily possible...

Some material of proper OD (wood - cut to size, steel pipe, PVC pipe)
A bunch of metal rods (thin welding sticks if nothing else)
A zip-tie or tie method / O-ring to hold the rods to the outside of the base material

I don't anticipate the rods would slide as readily as the "manufactured" tool, but if it'd be a rare-use tool, it might be a decent option.

[CS79bronco]

I may try tinkering with this. If I could find a magnet the correct size, or magnetize something might work. Surely I can come up with something, I think those Pipemasters are about $100 each aren't they?

[Haku]

I may try tinkering with this. If I could find a magnet the correct size, or magnetize something might work. Surely I can come up with something, I think those Pipemasters are about $100 each aren't they?

More like $40-60 depending on the size you get. The 4 piece set for multiple tubes sizes is $225 or so if you get them from the right place (Summit Racing and JEGS have them at that price).

I definitely find notching to be the hardest part of cage building. I've scrubbed a lot of tube just because I didn't get the angle quite right. Those PipeMaster's seem cool, but I've talked to guys who don't like them since it can be hard to fit them in some places at the right angle. Its also a lot of money for a piece of plastic with some holes drilled in it and small metal rods pushed through them, even if they are super stiff special alloy something or other.

Honestly, for the money you would spend on the pipe master you can spend just a bit more and get Bendtech Pro (its $275) and use the "cutting wrappers" feature...


http://www.youtube.com/watch?v=iLS49NvaBdk

There are more basic versions of Bendtech (EZ and EZ 3d) but they only let you work with a single piece and no notching print outs. The Pro version allows you to design a full cage and prints out sheets on exactly where and how much to bend it, then you can use the cut sheets to do your notch perfectly.

Some people out there can visualize a cage and bend it exactly just using basic tools and some chalk drawings, but I'm not one of those people and Bend-Tech makes it much easier to figure out. If anyone wants to come try it out, I'd be happy to meet you at the Club Workshop or bring my laptop to a trail run and let you fool around with it.

I find the hardest part for me is measuring existing mounting points and roll cage features, since you need to connect the new cage you are designing to them. Other then that, its just getting the calibration right for your bender so it knows what adjustments to make (it accounts for variables in your bender that can throw things off).

Sorry, not much help with your top Tube Alec, but I'm sure you'll figure it out.