Minimalist Cage Designs

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    Minimalist Cage Designs

    So... since the tech is here I thought I'd start a new thread since I am looking for information that pre-dates 2010. Since then everyone is all about curved tube chassis and zero new tech at Pirate.

    Building a cage is way down the list but I'd like to start some good discussion about it.

    I am building a CJ2a/3a and space is at a premium.
    A properly designed is 100% better than no cage but this is not a desert runner, no high speed stuff but it will be used on the street. So with that in mind, I'd like to keep myself safe on the street and not ring my bell since I won't be wearing a helmet on the road, off road is a different story.

    I love Meisers Rango cage... and it is something I will likely duplicate



    Is there a minimum tube size I can use? If I use smaller material can I increase the wall thickness to compensate for strength?

    Let's get some discussion going!

    #2
    1.5" x 120 should be big enough if designed right.

    Comment


      #3
      Why go smaller and thicker?

      1.5"x120 is good for lighter rigs I just did a cage for Wilson on his samurai out of 1.5" chromo, we did 120 A-C pillar run and 090 everything else.

      Personally I like 1 3/4" I think it just looks more correctly sized.

      The cage pictured is basically how I would do it, I'm a fan of running the tube from the A pillar to the C pillar instead of hoops running side to side. Looks better and is more functional imo.

      Comment


        #4
        Originally posted by [memphis] View Post

        A properly designed is 100% better than no cage but this is not a desert runner, no high speed stuff but it will be used on the street. So with that in mind, I'd like to keep myself safe on the street and not ring my bell since I won't be wearing a helmet on the road, off road is a different story.

        Is there a minimum tube size I can use? If I use smaller material can I increase the wall thickness to compensate for strength?

        Let's get some discussion going!

        OD of the tube has more of an impact on resistance to bending than wall thickness does.

        I'm in the same boat as far as being driven on the street. I went to great lengths to keep the cage away from my melon.
        Kevin

        Comment


          #5
          I don't see why not to use 1.75". it doesn't look too thick for a small jeep. The majority of mine is 1.75" .120, with a few 1" .120 for mounting the seats, belts, and grab handles. Mine is similar to Brennan's, with a few extra pieces in there.
          - Buck

          Comment


            #6
            Rango's cage is bitchin for sure.. Is jesse haines on here yet? He has built some awesome minimalist cages on his flatties over the years as well. Following along to get ideas for a future project or two.

            Comment


              #7
              I used 2" for my main rails on my XJ thing. Looks good size wise, agree that 1.75" should be min.
              ....Just Add Lightness...

              Comment


                #8
                needs overhead protection, going to the roof on anything other than flat ground is asking for some serious problems.

                Comment


                  #9
                  General rule of thumb for tube diameter is under 4k lbs then 1.5" x 0.120" is good, between 4k - 5k lbs use 1.75" x 0.120, over 5k lbs use 2" x 0.120". This is more or less what various sanctioning bodies require.

                  Here are some pics of the "minimalist" cage for my TJ-looking buggy. I still want to add some crosses in the back (to mount a spare tire) but have not come up with a design that I like.

                  As designed in Solidworks:

                  Click image for larger version  Name:	cage-001-x.jpg Views:	0 Size:	59.4 KB ID:	48488

                  Transferred into Bendtech:

                  Click image for larger version  Name:	bend-tech-001-x.jpg Views:	0 Size:	90.6 KB ID:	48489

                  As built:

                  Click image for larger version  Name:	IMG_20200112_185235.jpg Views:	0 Size:	126.0 KB ID:	48490

                  Click image for larger version  Name:	IMG_20190309_190557305.jpg Views:	0 Size:	152.7 KB ID:	48491

                  Click image for larger version  Name:	IMG_20191117_184933.jpg Views:	0 Size:	139.7 KB ID:	48492
                  Last edited by Eric; 06-23-2020, 07:24 PM.
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                  Redneck-at-Large

                  Comment


                    #10
                    Originally posted by mobil1syn View Post
                    needs overhead protection, going to the roof on anything other than flat ground is asking for some serious problems.
                    I've seen alot of cages that the top B pillar connector folds in when the rig rolls over backwards or forwards, even on slow once overs. I can't really imagine the cage not racking over if you laid it over on it's side, without a X.
                    ....Just Add Lightness...

                    Comment


                      #11
                      Originally posted by Weasel View Post

                      I've seen alot of cages that the top B pillar connector folds in when the rig rolls over backwards or forwards, even on slow once overs. I can't really imagine the cage not racking over if you laid it over on it's side, without a X.
                      i was referring to a rock impaling the occupants.

                      i would not feel comfortable in the cage the OP posted

                      Comment


                        #12
                        Originally posted by Eric View Post
                        General rule of thumb for tube diameter is under 4k lbs then 1.5" x 0.120" is good, between 4k - 5k lbs use 1.75" x 0.120, over 5k lbs use 2" x 0.120". This is more or less what various sanctioning bodies require.

                        Here are some pics of the "minimalist" cage for my TJ-looking buggy. I still want to add some crosses in the back but have not come up with a design that I like.

                        As designed in Solidworks:

                        Click image for larger version
Name:	cage-001-x.jpg
Views:	446
Size:	59.4 KB
ID:	48488

                        I’m interested in your thoughts on these (see red ovals). What will they connect to in the front? Any concern about the hoop at the A pillar handling the load mid tube?

                        Click image for larger version
Name:	Cage.jpg
Views:	345
Size:	67.8 KB
ID:	48627

                        While we build the suspension in our Scout we’re thinking about the cage we will eventually build. It came up now since it seems logical to brace the front shock hoops to the A pillar hoop. Then, where does the load go from there?

                        Comment


                          #13
                          Originally posted by OC IH View Post

                          I’m interested in your thoughts on these (see red ovals). What will they connect to in the front? Any concern about the hoop at the A pillar handling the load mid tube?

                          While we build the suspension in our Scout we’re thinking about the cage we will eventually build. It came up now since it seems logical to brace the front shock hoops to the A pillar hoop. Then, where does the load go from there?
                          it prebuckles the a pillar on the endo, so it collapses when it hit the brow bar.

                          Comment


                            #14
                            Originally posted by mobil1syn View Post

                            i was referring to a rock impaling the occupants.

                            i would not feel comfortable in the cage the OP posted
                            Depends on what you are doing. Its similar, probably better, than a factory TJ cage and I've seen those hold up remarkably well. Of course you are not going to take it out desert racing and it probably would not fare too well during a 300 foot barrel roll but out on the "easier" trails it serves fine for a "minimalist" cage. And then we have this guy:

                            Click image for larger version  Name:	maxresdefault.jpg Views:	0 Size:	221.1 KB ID:	48695
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                            Redneck-at-Large

                            Comment


                              #15
                              Originally posted by OC IH View Post
                              I’m interested in your thoughts on these (see red ovals). What will they connect to in the front? Any concern about the hoop at the A pillar handling the load mid tube?
                              These pieces connect to some tube work in the front that is permanently welded to the frame. They are there for aesthetics and are not intended to be primary load bearing structure. The frame itself is 2" x 4" x 0.188" tube. There are a number of places on the cage, and the front tube work, where I intentionally deviated from "proper" node design for (mostly) aesthetic reasons. This is a full-frame rock crawling trail rig that will see very low speed flops onto the side or roof. If racing was part of the picture I would have built a full-tube space frame.
                              Last edited by Eric; 06-23-2020, 07:29 PM.
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                              Redneck-at-Large

                              Comment

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