How to weld a roll cage...

[GsxrMike]

How do you guys weld the seams of your roll cage that you can't get to? Like the upper cab corners etc. I did some research on the subject and didn't find much on that issue.

Also I am not a trained welder but I have a miller 170 and I have welded several things that held together fine including then end on to a 2" hydrolic ram on a trencher. What tips do you have about welding tube. I read not to get it "to hot" because it will make the metal brittle.

As always -

 

[4-play]

1st, I haven't done it. From what I gather, you can access the tubing by cutting out the floor and dropping the cage down in there before final attachment. Some even remove the windows to help gain access. I know I didn't explain it that well but hopefully you get the jest. I'm sure others with experience will chime in.

 

[cybrfire]

Stand on your head, hang from the ceiling, inverted grip with your truck up side down.

A lot of contortion. In the end, the best way is to tack everything where its easily acessible. Then crack the tacks loose and drop assemblies down to where you can weld and then stand them back up. Planning the joints for this purpose helps, but no matter what, you'll probably have a couple that are a complete bastard.

Cut holes in the floor, never resorted to that so far. I think I'd rather cut the roof off.

 

[colbystephens]

I read not to get it "to hot" because it will make the metal brittle.

I don't think that's quite correct. I believe it reduces the yield strength of the material and makes it more malleable. DOM tubing is drawn in such a way as to make it stronger, when you heat it, it loses that rigidity. However, you're making up for the loss of rigid strength by having a joint at that point such that when it gets loaded in a roll - the load is distributed in different directions.

 

[badmix]

Having the top of the cage not permanent yet helps.

but, yea you gotta get creative.

 

[colbystephens]

i like your jerry can holder! i highly recommend you wear better welding clothing tho. just a matter of time till you end up with a nasty sun burn or some nice burn scars...

 

[blazinzuk]

Most 4wd vehicles that I have done you can get enough room to weld around the cage. I have done some cars and we did have to cut holes in the floor in that one to get the very tops of a couple of joints, but I knew that from the begining so it was easy to plan for

 

[81jimmyslt]

Best way for us is too keep the front section tacked together and disconnect tacks @ a pillar. Slider rear section of cage back a bit and tilt front section down to weld. Tape and mask windows, plactic, and roof liner, burns up fast!

 

[wayne]

I did mine in 2 sections. It was a pain to take out and put back in with just the wife and I.

I am getting ready to do more work to it now. I am adding door bars, some gussets, and cross bars behind the seats to X it.

 

[ktmoutfront]

I found a miller mini tip for my 250. It is smaller than the standard tip and can get into smaller areas.

I will also turn up the heat and gas and run the wire out farther. It takes some time to get used to welding in tight spaces.

 

[tRustyK5]

Use the gasless wire for the tight sections, and remove the nozzle entirely...

Rene