Long Travel BS Thread

If you have both talked to him and he still doesn't get it there's no one else to blame but himself when he gets it back. I'm not sure why or how he came about to choose the shop he did to build his truck when they have never built a desert truck before but his whole build has been pretty hack in my opinion. The perfect example is the original mock up of his rear coilovers and bypasses which have since been moved but . The truck is covered in dead tubes and pointless bends that don't add any structural support and look ridiculous. He's getting taken for sure but that's really none of our business.

That being said, the rear window on a Double cab is probably the most difficult part of the truck interior to cage if you are trying to seat 4 people but still be structurally sound. It is the one part of my cage that I am not 100% happy with. We had originally dropped 2 tubes at a 45* angle from the c-pillar top corner junction to the center junction just under the sliding rear window, the 45* tubes were mirrored to the lower C-Pillar corner junction as well so 4 tubes all landed in the same place in the center of the back wall just under the window. But the way the seats sat pushed the headrests right up against the upper 45* tubes and created a hazard for anyone sitting in the back seat to potentially knock themselves out if their head ever went backwards. The upper 45s were cut out and we replaced it with a single straight tube that drops directly down to the junction through the middle of the sliding rear window so now 3 tubes all land at the same junction that originally landed 4. Structurally, not quite as perfect as the four 45s but way safer for anyone in the back that isnt wearing helmets.

crap pictures but you can see the issue and the fix.

Original Layout:




Corrected:

 

@tubbsisland you can see how we ran mine here.

 

yea but a) your seats are way taller than mine and If I had run a taller seat it would have been a non issue where the tube were originally and b) you had to run 2 extra tubes in order to do it. Structurally stronger yes, but I'm still confident mine would hold up just fine in the event of a roll.

mine was just a freak thing of the right seat height in conjunction with the tubes laying at just the right (wrong) location.

 

Are those center tubes curved around the headrests?

 

looks like the have a small bend in them

 

Boom two examples of good ways to do it

 

Since I had to finish my cage from the PO it was pretty terrible. Also I don't know how to fuck to notch a 45 tube in a area that has the two Horizontal tubes already. This junction is my worst one by far and I. An probably fit my finger in the top hole.... I wish I would have re done it lol......

 

Genius - nobody ever remembers to leave pressure relief holes at multi tube junctions. Most people don't realize how dangerous it can be if there is nowhere for the internal tubing pressure to go ...all these weld porn tig'd cages are f-n grenades just waiting to go off

 

I've been fabricating for 18 years, and let me tell you that this is how it is done. Also use jb weld instead of mig/tig for better flex

 

Curious to why you didn't c notch? I don't think metcho notched his either.

 

45's or any compound notch can hurt your brain just got to remember to notch each side of the tube seperatly, it's a hell of a lot easier to do with an actual notcher

 

I wasted soooo much tube and finally said fuck it. Good notcher would have helped. I did two 45s and the tube wouldn't fit cause the top lol.

 

Yea, and trying to put a 45 in an existing box is a real bitch

 

On another note I absolutely despise welding thin ass sheet metal together

 

That's why I gave up ):

 

I hated that part hahaha

 

These things help with weird notches

 

That thing is rad! I want one, that's better than my masking tape mock up tubes and taking angles off the tape

 

They work pretty good, the needles flex a little but it gets you close