How to Build 4X4 Roll Cages
A 4x4 is an off-road vehicle designed for tough terrain. Usually these vehicles have larger wheels, thicker tire treads and advanced suspension that allows them to climb up hills and mountain trails. The rough terrain also means that the vehicles are at risk of tipping. Due to this danger, most 4x4 trucks have an added safety feature, a roll cage. This is a project for avid off-road drivers and those with knowledge of welding.
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Instructions
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Design your roll cage to protect the exterior of the vehicle including the headlights, hood, wind shield and rear tail lights. Each vehicle is very different in shape, so the dimensions and design of your cage will depend on the shape of your vehicle. Start by measuring the hood and rear end of the vehicle and build the cage in sections attaching the front and rear after each is fully constructed.
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Cut the 3-inch steel pipe at 45-degree angles using a metal saw or pipe cutter. It is important to fit the pieces together at an angle to increase the roll cage's strength. Each section will also be fitted to the vehicle frame using steel pipes and brackets.
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Weld the joints using a MIG welder and No. 3 filler bars. Clamp each pipe into a vice, situating them flush along the angle so the seams line up perfectly. Weld the seams with a continuous bead. After each weld, grind the weld flat with a metal grinder.
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4
Attach the roll cage to the frame of the vehicle by welding the cage directly to it where possible. Depending on the type of vehicle you operate and the shape of your cage, this may also involve attaching the cage to brackets with steel bolts. Cut custom brackets from solid steel, 1/2-inch plating using a metal saw. Shape the brackets to the cage and frame using a torch and metal benders.
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Finish the cage with automotive primer and a rust-proof automotive finishing paint. This protects the cage from rust and corrosion.
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