Had a request to build a simple roll cage on a mid ’80’s Toyota offroad truck. The design came out simple and affordable, yet strong enough to protect the occupants in a rollover.
Obviously there could have been more tubing added to the truck but with <100hp the owner and I decided that there isn’t a real large risk of a high speed collision or rollover.
A great place to start research for offroad specific roll cages is Pirate 4×4.com. There is some great info in the Roll Cage 101 post for those that are interested.
On to pictures!
The somewhat blank slate.
The mini-bed that had to be removed before we could get started.
Flatbed removed and ready to bend some tube!
The main “halo” tube. Takes a lot of measurements and patience to get 6 accurate bends in one piece of tubing.
Added “fish plates” to the frame where the main halo attaches. Notice the plate doesn’t have any long straight edges that might cause stress risers which could eventually fatigue and crack the frame.
Adding triangulation behind the cab for more support. (lots of info about triangulation on Pirate4x4.com)
Added two rear down bars.
Built a frame extension so we could install a new flatbed.
The finished product! Looks a lot better than the sketchy wood flatbed that was barely attached, and a lot safer if this truck ever had a rollover off-road.
This turned out to be a fun project that could be finished in one full day’s worth of work depending on the complexity of the design. Since this was an external roll cage, it went a lot faster than trying to install one inside of the cab.