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full roll cage in manx clone
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DSTMULE
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PostPosted: Sun Mar 23, 2014 8:07 am    Post subject: full roll cage in manx clone Reply with quote

New to fiberglass buggies and would like to put a full cage, I have a single roll bar now, it's nice but would like a little more.
Any suggestions? does anyone make a universal cage? sounds scary and a headache or recommendations on having a cage built in southern California area?
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VOLKSWAGNUT
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PostPosted: Sun Mar 23, 2014 8:16 am    Post subject: Reply with quote

Start searching this forum.. better yet read the many topics already on the subject.

http://www.thesamba.com/vw/forum/search.php?search..._chars=200
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Dale M.
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PostPosted: Sun Mar 23, 2014 8:20 am    Post subject: Reply with quote

I have never seen a full cage kit or assembled unit (bolt in) for FG cars on market.... Both of my buggies have had custom fabricated cages made by local "chassis/cage" builders.... Preference was .120 wall DOM tubing of 1.5 or 1-5/8th inch diameters....And side rails hopefully to protect from side impacts (never tested!).... Finish is powder coat gloss black...

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To secure cage to tub/floor, a full "plate" was fabricated to sit on lip of pan/tub to stiffen floor and give better structure to chassis....Also note tabs were added to cross bar behind seats for shoulder harness and also at bottom rear corners for outboard seat belt anchors.... And tab to front hoop between bars for rear view mirror mount.... Its the little things ....

Dale
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Last edited by Dale M. on Sun Mar 23, 2014 8:35 am; edited 3 times in total
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DSTMULE
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PostPosted: Sun Mar 23, 2014 8:27 am    Post subject: Reply with quote

Thanks Dale M. That cage is perfect you have. Guess I will have to look around the southern California area.
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Dale M.
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PostPosted: Sun Mar 23, 2014 8:42 am    Post subject: Reply with quote

Only thing I would do different is bring two center bars forward, level then slight bend down to meet front hoop.... The setup I have as is, is close to being a head banger....

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When you see angle as car sits with cage installed, the bars going forward would be technical level to ground and not look "humped" up .... (see previous pictures)...

Dale
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DSTMULE
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PostPosted: Sun Mar 23, 2014 8:57 am    Post subject: Reply with quote

something to keep in mind when I get one, Thanks Dale.
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lostinbaja
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PostPosted: Sun Mar 23, 2014 9:10 am    Post subject: Reply with quote

I moved the overhead bars outboard a bit and put the bend in the overhead bars to keep from bouncing our heads off of them when cruising the dunes.

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joescoolcustoms
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PostPosted: Sun Mar 23, 2014 6:59 pm    Post subject: Reply with quote

Texas Buggy's used to make a prefab cage for a buggy, do not know if they still do, but a call away and you can know.

http://www.texasbuggys.com/

I have one or two cages for buggy's and the materials usually cost about $ 250 to $ 300. Includes 1 5/8" 0.120 wall DOM Tubing, 1/4 inch thick seal plate from front to rear of pan bolt flange area, welding supplies, and paint. I would allow $ 1000 to $ 1500 for a shop to build one and supply the materials.

I usually go up under the dash/hood area and add another 1" diameter hoop as a steering column brace. Take them to the rear and tie it int the rear frame bolting through the FG Tub.

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ChadCook
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PostPosted: Wed Mar 26, 2014 10:38 am    Post subject: Reply with quote

I'm working on fitting the Acme show cage kit to my Clod Hopper. Its made to fit one of their bodies so its not a bolt in. With a little imagination its turning out pretty good. I'll post some picts once its tacked together.
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wythac
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PostPosted: Wed Mar 26, 2014 10:52 am    Post subject: Reply with quote

Not being the accomplished metalsmith that Mr. Joecool is, I think if I built another cage I would order one of a few options for full cages available for offroad beetles and modify it to fit.

Of course I say that not having tried it before. Having remodeled a few old homes, I've sworn that my next terrestrial project will be all new construction, so I might just be talking out my ass here in thinking a modification of an existing cage would be easier than bending another one up out of straight tube.

Good news locally for me on metal prices...after a spike a few years ago the price on 1.5" DOM has dropped back out of the stratosphere... I paid less than 3.00US/ft for a 20 ft stick of .120 wall last week.

Several years ago I contacted Neil at Hawkeye Buggies in Texas about bending up a custom cage for me. His fee was reasonable, shipping from Texas to the PNW was not, so I opted to buy a wire feed and brush up on my rudimentary welding skills. He might be an option for you if he is still in business, he used to have his contact info here on thesamba somewhere.
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joescoolcustoms
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PostPosted: Wed Mar 26, 2014 12:01 pm    Post subject: Reply with quote

Ha Ha!

I am not a "Metal Smith", I just know how to take pictures.

After the couple of cages I have done, I doubt I would modify a Beetle cage. They are made for a wider car, so the main hoops would have to be cut in the center, narrowed and re-welded. Now that can be done safely by using a sleeve on the inside of the joint. And you are stuck with the design of the Beetle cage.

To do it yourself, the hardest part is swallowing the price of a bender, the rest is not that hard if you can remember a little Geometry. Having a buddy go in with you on a tool is a great way to do it.
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Dale M.
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PostPosted: Wed Mar 26, 2014 1:06 pm    Post subject: Reply with quote

This site has all the knowledge you need to make perfect bends in the right places to succeed in your project...

http://www.pirate4x4.com/tech/bendin_tube/index.html

Also they have some really good tech articles on various benders... and tools and fabrication processes...

http://www.pirate4x4.com/tech/

http://www.pirate4x4.com/tech/billavista/Bender&Notcher/Bender/
http://www.pirate4x4.com/tech/billavista/Bender&Notcher/Notcher/

Dale
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wythac
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PostPosted: Wed Mar 26, 2014 1:41 pm    Post subject: Reply with quote

Joe,

I'll check that box as a bad idea then. I guess I have always figured that the beetle cage that fits inside the floorpan would fit inside the floorpan of a buggy as well. You might need to cut it down for height and length but since it would have to come as a knockdown anyway you could do that without sleeves by cutting the end(s) of the different sections of tube.


As I mentioned though, it isn't something I have tried. I have used 1.25" DOM as an inner sleeve for putting together "scraps" of 1.5" DOM for non structural components, but I don't see any wisdom in doing that on hoops or other major structural components.


To the original poster, if you don't have room or tools or skills or time (!) to fabricate your own cage, start looking around your community for a 4x4 shop. Their customers are breaking stuff constantly, and need access to talented welders if they don't have those skills themselves.

Good luck in your search. I would think in CA you stand a pretty good chance of finding someone to do the work for you.
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54Baja@14
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PostPosted: Wed Mar 26, 2014 5:46 pm    Post subject: Reply with quote

Something else to consider is, do You want the body to still be removable?
There are plenty of good fab guys in our area, mines a half breed, some in my garage & some professional help.
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Iguana
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PostPosted: Wed Mar 26, 2014 6:01 pm    Post subject: Reply with quote

54Baja@14 wrote:
Something else to consider is, do You want the body to still be removable?
There are plenty of good fab guys in our area, mines a half breed, some in my garage & some professional help.
Image may have been reduced in size. Click image to view fullscreen.
Image may have been reduced in size. Click image to view fullscreen.


Must say that is a very nice looking buggy and well balanced, you have done well
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DSTMULE
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PostPosted: Wed Mar 26, 2014 7:18 pm    Post subject: Reply with quote

very nice buggy & cage
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PostPosted: Wed Mar 26, 2014 7:56 pm    Post subject: Reply with quote

Lguana, do you have a build thread on that buggy?
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slalombuggy
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PostPosted: Wed Mar 26, 2014 10:55 pm    Post subject: Reply with quote

joescoolcustoms wrote:
Texas Buggy's used to make a prefab cage for a buggy, do not know if they still do, but a call away and you can know.

http://www.texasbuggys.com/

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Hey Joe, Really like this cage what pages in your gallery folder are more pictures of it on?

brad
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PostPosted: Thu Mar 27, 2014 6:16 am    Post subject: Reply with quote

slalombuggy wrote:
joescoolcustoms wrote:
Texas Buggy's used to make a prefab cage for a buggy, do not know if they still do, but a call away and you can know.

http://www.texasbuggys.com/

Image may have been reduced in size. Click image to view fullscreen.


Hey Joe, Really like this cage what pages in your gallery folder are more pictures of it on?

brad


Here you go Brad:
http://www.thesamba.com/vw/forum/viewtopic.php?t=556247&highlight=

I also have one on my current Manx build titled "Basket Case Manx II"

My first buggy cage was for a APC Sand Shark in 2006
Then a Lithia Mark III in 2012
A "X" Body in 2012
A Trantula in 2012
Another "X" body in '13
A Desert Fox in 2013
And late summer '14 will be another Manx II
Winter '14 - '15 will be a Viper
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Best Day Ever Racing 2022 NORRA 1000 2nd in Class and first All Female team to complete the race

Everyone is gifted. Some just do not open the package.

Looks like it was painted with a live chicken,polished with a brick and buffed with a pine cone
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streetbuggy8804
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PostPosted: Thu Mar 27, 2014 6:54 am    Post subject: Reply with quote

There is a guy on this site that rents a bender. He can also do the work for you. He lives in eastvale ca. His name is Craig. Great little service he provides. He also has the software to design the cage to your liking beforehand. He is an architect by trade so he is very capable of working and designing on that computer based software. Just search " bender rental" and reach out to him.
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