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    Litespeed's RZR-S cage build!
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    I decided to build myself a cage since I didn't like the way the factory one looked and mostly because I just wanted to. I bought a bender, a tubing notcher and of course from owning the "Crack-Kart" I already bought a mig welder back in 02. I also want a windshield made with automotive safety glass, a bigger roof and a rear windshield if you will for the rear to keep the mud off of me. I will make the front and rear windshields removable with Dzus fasteners so both can be removed in mins if i want that fresh air feeling or quickly install when it cools down or starts to rain...should be cool.

    I checked around to buy an aftermarket cage and they were from the cheapest at about $1000 for a raw steel "sport" one to $2500 for a crome moly "race" powder coated cage. Way to much for this working man and it looks simple enough. So first I needed a bender. When asking around online I got everything from the JD2 Model 3 at $295 plus stand and dies to computer guided benders that cost more than my house. I liked the JD2 Model 3 and a few of the like "clones" but those type manual benders you have to bolt to the floor and you need at least 12 feet all around it well at least I do because of my longest one piece tube I plan to bend. If you add hydraulics then you can make it movable but at a cost of about 500 bux on top of the bender, stand and die which is about right under $700 shipped to the house. $1200 is way too much for a project unless I turn out to be the next Jesse James.....

    So I found a simple hydraulic bender that was cheap and bends....Yea! http://www.tjdieselperformance.....der/Detail
    Is it the greatest? Prolly not but for what I need it will do perfect and on top of that I was able to get it on sale on e-bay for $310 shipped to my door. How cool is that? Only downside I know of right now is it will only bend to 90 degrees where most others will do 110 to 210 degree. I won't have any bends past 70 degrees so mine again will do fine. I did find out that I can only bend up to about 80 degrees.

    Next I needed a tubing notcher. Again asking online I got everything from a $80 dollar Harbor Freight one all the way up to a $5000 digital belt sander type. The one thing I read more times than any was don't skimp and buy a cheap light gauge one. They use a hole saw to cut the pipe and are attached to shaft. The cheaper ones have 1/2 to 5/8" shafts, bronze bushings and thin body's and they flex a lot. I ended up with a JD2 "Notch Master" after reading
    fantastic things about them. JD Squared, Inc. This thing is a monster. Weighs in about 30 pounds and super solid. Has sealed bearings, 1 inch shaft all on a solid steel frame. No chatter from this dawg!!! I found this also on e-bay and got it shipped to my house for $265. When I got it and went to put it together there were pieces that didn't fit. A call to the manufacture and they sent me new parts...wrong notcher, crap. I called back and they sent out another part....it was the same as the other one so the last shipment was the whole assembly. It's all good cause they took care of me, it's what a good company does and JD2 is just that.But you know who I'm talking to/about!

    My Welder is a Clarke 135 amp 110 volt el-cheap-O. I paid about 450 bux way back but it welds good...well as good as I can and most parts interchange from the so called better brands. Clarke actually went out of business this last year due to the economy...bummer.

    The stock RZR cage is made from .063 or .065 (I forget which one!) 1 3/4" tubing. Most seem to build out of .095 to .120 which in my opinion is way over built on a car that only does 65 mph on it's best day. The stock cage will protect you if you crash but it will fold up. I have seen many. But many forget that it what it is suppose to do, absorb the energy of impact so your body does not. Like cars today with their special frames and bumpers. Don't forget
    the vehicle is expendable, not the people inside. If your dead you can't drive the car anyway so what does it matter. Since my welding "skilz" are not all that they could be I didn't want to try welding the .063 anyway and don't mind a bit stronger cage so I went with 1 3/4" x .083 ERW tubing. Plenty strong for my application and cheap. I'll be using 12 gauge steel for the flat work pieces at the rear, upright brackets and front bumper mount.

    All the pipe to build the cage, front and rear bumpers and plate material was around $200....for a $1000 dollar cage...not a bad profit if I say so myself. I'll still need to get the 4'x4' 12g aluminum for the roof and a couple 2'x4' pc of 1/8" for the front and rear windshields but those will be under $75 combined. Glass installed front and rear should be under 300 bux.

    On to the pictures and updates as they happen,

    Tom
    Last edited by litespeed; 03-14-2010 at 03:56 PM.
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    Re: Litespeed's RZR-S cage build!
    #2
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    More pictures,
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    Re: Litespeed's RZR-S cage build!
    #3
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    More.....

    Most of the cage is done. Need to add 4 more bars. One to bottom and top of front windshield area, one between the uprights for the seat belts to wrap around and last but not least one between the rear bumper uprights to transfer the load from the main cage loops. I also plan to add some bracing to the rear "windshield" area also, they will probably be just short angled tube piece coped from roof to upright.

    The welding is harder than I thought it would be. Starting and stopping sure makes it hard to do good looking welds. I'm actually having a harder time welding around these arks as well. Doing a straight gusset is so much easier then keeping the gun tip the same distance all the way around. There are going to be some grinder marks when it's finished.....just overlook them! Smile

    Feel free to throw out any pointers you may feel relevant. I should be done with the cage by the weekend and starting on the front bumper and roof.

    Tom
    Last edited by litespeed; 03-14-2010 at 03:56 PM.
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    Re: Litespeed's RZR-S cage build!
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    Ditto.....
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    Re: Litespeed's RZR-S cage build!
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    Again....
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    Re: Litespeed's RZR-S cage build!
    #6
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    See if you can guess......

    I finished all the bars and they are all installed. The whole cage is only partially welded and has to be removed to finish it. I added a tab for the rear view mirror and still need to add a tab for the dome light and a couple for flags. I'll probably add the flag mounts either at the rear bumper on both sides or somewhere on the rear down tubes on the main cage.

    Any suggestions of anything to add while it's still raw paint?

    I'm debating whether to add grab handles where the windshield and roof come together. I have some 1" tube I could use. What do you think about that?

    Tom
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    Re: Litespeed's RZR-S cage build!
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    Looking good Tom. Definatly will be a lot safer than the OEM.
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    Re: Litespeed's RZR-S cage build!
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    Intense Moderator Rat4020's Avatar
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    very nice !Looks way better than the stock . Prob a lot stronger also. One question what about the cooler rack???I didnt see one...
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    Re: Litespeed's RZR-S cage build!
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    How do you like that after being in a 100 plus MPH nachine?
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    Re: Litespeed's RZR-S cage build!
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    Quote Originally Posted by Odyknuck View Post
    How do you like that after being in a 100 plus MPH nachine?
    I'm also wondering how you like the RZR-S after the minibuggies? Good looking work on the cage! You might want to consider adding a flag mount on the front bumper.
    I race, therefore I am
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