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Old 05-21-2010, 11:24 AM   #1
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Default Build your own exo-cage, exoskeleton...don't buy one!

I looked long and hard to get some ideas relative to how to build an exo-cage for my 89 XJ. Knowing that I could purchase one for around a $1000 made me really think.... but I had to find a way to justify buying a tube bender... one that my wife would buy into! So Santa brought me a tube bender for X-mas, which when all was said and done cost about $850.00. I worked at trying to figure out how to make simple bends prior to diving into to a pile of .120 13/4 DOM and ultimately decided it was "Baptism by Fire" baby! So I started in a what turned out to be alot of fun to build and man is it strong!
I started with the rock sliders, and then just started adding a piece at a time following the contour of the jeep. I would bend a piece and tack it into place, then on to the next. Mind you, I have never built one before, but I think it turned out OK. My rear doors even open all the way, which I was pretty sure would not be the case, but it worked out! I'm into it about $600.00 in materials and have a new tube bender in the shop to boot! There are some tricks that I learned along the way! Here are some pics of our this years trip to Moab, Utah. Hope this helps someone else with some ideas.....
Attached Thumbnails
Build your own exo-cage, exoskeleton...don't buy one!-looks-broke-me.jpg   Build your own exo-cage, exoskeleton...don't buy one!-steelbender-pops.jpg   Build your own exo-cage, exoskeleton...don't buy one!-oh-yea-.jpg   Build your own exo-cage, exoskeleton...don't buy one!-copy-2-dscn1308.jpg   Build your own exo-cage, exoskeleton...don't buy one!-copy-2-dscn1146.jpg  

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Old 05-21-2010, 11:57 AM   #2
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Damn that's sick, That's really nice for a first timer too! You got some monster rear flex too. Can you PM me about your rear susp. set up?
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Quote:
Originally Posted by hussler737
Well cause.... Barbie drives a Wrangler. I can't be associated with that bimbo.
"No mud permitted on vehicles, Please remove mud from parking space"
Oh really? Do you have a shovel?
"No"
Neither do I!
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Old 05-21-2010, 12:16 PM   #3
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what did you use for toob?
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Old 05-21-2010, 12:17 PM   #4
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Quote:
Originally Posted by Rock'n BB View Post
I looked long and hard to get some ideas relative to how to build an exo-cage for my 89 XJ. Knowing that I could purchase one for around a $1000 made me really think.... but I had to find a way to justify buying a tube bender... one that my wife would buy into! So Santa brought me a tube bender for X-mas, which when all was said and done cost about $850.00. I worked at trying to figure out how to make simple bends prior to diving into to a pile of .120 13/4 DOM and ultimately decided it was "Baptism by Fire" baby! So I started in a what turned out to be alot of fun to build and man is it strong!
I started with the rock sliders, and then just started adding a piece at a time following the contour of the jeep. I would bend a piece and tack it into place, then on to the next. Mind you, I have never built one before, but I think it turned out OK. My rear doors even open all the way, which I was pretty sure would not be the case, but it worked out! I'm into it about $600.00 in materials and have a new tube bender in the shop to boot! There are some tricks that I learned along the way! Here are some pics of our this years trip to Moab, Utah. Hope this helps someone else with some ideas.....
Quote:
Originally Posted by xjoffroad View Post
what did you use for toob?
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90 xj laredo - Grant steering wheel, 4.5" RE Extreme Duty Long Arm kit, 33x12.5r15 Kumho Road Venture M/Ts, 15x8 Cragar D-windows, Custom JCH Front bumper. Check it out- my build Project Ghostrider
Quote:
Originally Posted by hussler737
Well cause.... Barbie drives a Wrangler. I can't be associated with that bimbo.
"No mud permitted on vehicles, Please remove mud from parking space"
Oh really? Do you have a shovel?
"No"
Neither do I!
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Old 05-21-2010, 12:20 PM   #5
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my bad
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Old 05-21-2010, 12:23 PM   #6
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I dont like exo's and in PNW they will get caught on anything in the trail. Trees and roots love exo's because are trails are so tight. Here they are worthless. But you did a great job even for a first timer! Looks tight to the body also!
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Old 05-21-2010, 12:33 PM   #7
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my bad
Its okaaaay
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Originally Posted by xjoffroad View Post
I dont like exo's and in PNW they will get caught on anything in the trail. Trees and roots love exo's because are trails are so tight. Here they are worthless. But you did a great job even for a first timer! Looks tight to the body also!
Thats the key! I love exo's, but when I make one it's going to be insanely aggresive looking
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90 xj laredo - Grant steering wheel, 4.5" RE Extreme Duty Long Arm kit, 33x12.5r15 Kumho Road Venture M/Ts, 15x8 Cragar D-windows, Custom JCH Front bumper. Check it out- my build Project Ghostrider
Quote:
Originally Posted by hussler737
Well cause.... Barbie drives a Wrangler. I can't be associated with that bimbo.
"No mud permitted on vehicles, Please remove mud from parking space"
Oh really? Do you have a shovel?
"No"
Neither do I!
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Old 05-21-2010, 01:05 PM   #8
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The kid that I bought it from built it as one of his college "Stuctural Engineering" projects. It's all bolt on, no welds to the uniframe. I get 38" of flex before a tire leaves the ground!
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Old 05-21-2010, 01:14 PM   #9
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slick................
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Old 05-21-2010, 01:15 PM   #10
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Quote:
Originally Posted by Rock'n BB View Post
The kid that I bought it from built it as one of his college "Stuctural Engineering" projects. It's all bolt on, no welds to the uniframe. I get 38" of flex before a tire leaves the ground!
That's insane, what size tires do you run? Looks like 35s?
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90 xj laredo - Grant steering wheel, 4.5" RE Extreme Duty Long Arm kit, 33x12.5r15 Kumho Road Venture M/Ts, 15x8 Cragar D-windows, Custom JCH Front bumper. Check it out- my build Project Ghostrider
Quote:
Originally Posted by hussler737
Well cause.... Barbie drives a Wrangler. I can't be associated with that bimbo.
"No mud permitted on vehicles, Please remove mud from parking space"
Oh really? Do you have a shovel?
"No"
Neither do I!
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Old 05-21-2010, 01:29 PM   #11
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They are 35x12.50's
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Old 05-21-2010, 01:30 PM   #12
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Originally Posted by Rock'n BB View Post
They are 35x12.50's
Sweet.
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90 xj laredo - Grant steering wheel, 4.5" RE Extreme Duty Long Arm kit, 33x12.5r15 Kumho Road Venture M/Ts, 15x8 Cragar D-windows, Custom JCH Front bumper. Check it out- my build Project Ghostrider
Quote:
Originally Posted by hussler737
Well cause.... Barbie drives a Wrangler. I can't be associated with that bimbo.
"No mud permitted on vehicles, Please remove mud from parking space"
Oh really? Do you have a shovel?
"No"
Neither do I!
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Old 05-21-2010, 02:14 PM   #13
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I could swear i know that Jeep... you wouldnt be from Ohio and have a Dad who goes by TC?

Nice work, looks good.
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Old 05-21-2010, 03:04 PM   #14
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Nope, I'm from Utah
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Old 05-21-2010, 03:11 PM   #15
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Great job! I would love to have a tubing bender for exhaust at least. Bet you can get some small odd jobs and use it to make some extra change if you wanted.
I think if it were me I would put a removable bar across the doors about mid way up to protect them. Might get aggravating to move them but you could put one end on a swivel and a pin on the other end.
Wish we had places like that to play in around here
clint
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