- Location
- Grand Junction, CO
Willys Crawler 2.0 aka The Bastard
- Thread starter Greg
- Start date
- Location
- Grand Junction, CO
The new roll cage just arrived! It's another one of those DIY projects... 60' of 1 5/8" x .120 DOM tubing. Purchased it at Cage Works here in Grand Junction, CO. The price of steel is up 45% so far this year and these guys were able to give me the price they had set before the markup, which was great.
- Location
- Grand Junction, CO
Since I had the tube, I decided to jump right into building the cage. It's been YEARS since I've done anything like a cage and I was using a new style bender, with air over hydro so I was a little nervous to start. I'm using a 'CarlBender', with JD2 Model 3 dies.... I believe it's a copy of a Pro Bender. I have 1 5/8" and 1 1/4" dies, so that's what I'll be using. The new bender makes building a cage SO MUCH EASIER! 
I'm used to hand cranking and repinning... none of that! 😍
I have been measuring and fitting up the seat, deciding what angle I want the A pillar at, figuring out the overall height and head room, seeing where it would all fall and how I can make it safe & strong. I don't have my floor plates yet (ordered 4" sq drilled plates) so nothing is permanent. Just fitting things up and seeing where it will all fit, getting the main structure laid out, etc. I plan to add plenty of triangulation next.
Right off the bat, I jumped into the A pillar upright.... with a compound bend! I kicked the bottom forward and in, for a little more foot room getting in & out. Plus, it will make tieing into the frame easier.
The A pillar will consist of a node and square joints at the top outside corner, rather than a bend. I want it to resemble a factory windshield frame, as I don't plan to run one. There will be more triangulation added to the roof, then an 'X' at the B pillar and a horizontal bar for the shoulder harnesses. I'll also add a 'A' to the windshield frame in the center with 1.25" tube.
The CarlBender at work! Love this thing! @I Lean
Main structure, more tube to come!
At this point, the roll cage is about 6' 2" off the ground.... shorter than I am, which was my goal. And the Willys is sitting about 1-2" higher than the ride height I want, so in the end the cage should end up at 6' tall, once it's all said and done.
I'm used to hand cranking and repinning... none of that! 😍I have been measuring and fitting up the seat, deciding what angle I want the A pillar at, figuring out the overall height and head room, seeing where it would all fall and how I can make it safe & strong. I don't have my floor plates yet (ordered 4" sq drilled plates) so nothing is permanent. Just fitting things up and seeing where it will all fit, getting the main structure laid out, etc. I plan to add plenty of triangulation next.
Right off the bat, I jumped into the A pillar upright.... with a compound bend! I kicked the bottom forward and in, for a little more foot room getting in & out. Plus, it will make tieing into the frame easier.
The A pillar will consist of a node and square joints at the top outside corner, rather than a bend. I want it to resemble a factory windshield frame, as I don't plan to run one. There will be more triangulation added to the roof, then an 'X' at the B pillar and a horizontal bar for the shoulder harnesses. I'll also add a 'A' to the windshield frame in the center with 1.25" tube.
The CarlBender at work! Love this thing! @I Lean
Main structure, more tube to come!
At this point, the roll cage is about 6' 2" off the ground.... shorter than I am, which was my goal. And the Willys is sitting about 1-2" higher than the ride height I want, so in the end the cage should end up at 6' tall, once it's all said and done.
- Location
- Grand Junction, CO
Thanks, I'm super happy with how it's coming together. The real work starts now, with the floor plates, coping joints, adding bracing, etc.
Same here, nice lines!
- Location
- Grand Junction, CO
The 37" Krawlers are great and all, but a set of 39" Red Labels came up locally and I had to snag them! I wanted to eventually run 39's, but it looks like I'll jump right in to the big tire club. ( Are 39's still considered 'big'?) I might as well build the suspension around 39's from the get go!
Now to dismount the 37's off the beadlocks, then mount up the 39's.... 🙄 Anyone need a set of 37" Krawlers??
Now to dismount the 37's off the beadlocks, then mount up the 39's.... 🙄 Anyone need a set of 37" Krawlers??
Pile of parts
Well-Known Member
- Location
- South Jordan
I thought so until I parked between these two at the Bewilder off road show last summer. 45s and 43s can give a guy a complex. Got a good deal on a set of 43s not tool long after... However, BFGs run a lot more true to size than TSLs. So I will consider you a member of the big tire club.
Pile of parts
Well-Known Member
- Location
- South Jordan
43s
- Location
- Grand Junction, CO
I think my Willys on 39's will look similar in proportions to your CJ7 on 43's....
Pile of parts
Well-Known Member
- Location
- South Jordan
For sure. I think its looking (will look) great! Can't wait to wheel with you.I think my Willys on 39's will look similar in proportions to your CJ7 on 43's....
RockChucker
Well-Known Member
- Location
- Highland
Ha! And I wouldn't consider BFGs as true to size...for the most part. My 39" KM3s are barely over 38"...I guess my 40" KR3s are pretty dang close to 40". In my experience, BFGs run small.
- Location
- Grand Junction, CO
These 39's measure 38 1/2" unmounted, I think the 'race' tires are closer in size than the 'street' tires.
RockChucker
Well-Known Member
- Location
- Highland
That would make sense. Somewhere I have a pic of a 37” mtr next to a 39” krawler and they are basically the same size
- Location
- Grand Junction, CO
Holy hell... yeah, that'll do! 39's under the Bastard!
- Location
- Grand Junction, CO
Me too!
AND his Willys!
I'm just glad to finally know you love me, Carl.
