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Excursion Roll CageJuly 24th, 2007
I've been doing some pretty tough 4 wheeling in the Rockies this summer. The only times i've parked my truck and ridden in other vehicles are when my truck starts acquiring scratches. I've gotten quite a few. My goal is to protect my paint and body so that i can attack harder trails without damage. I love driving this surprisingly capable vehicle and want to make this truck more capable instead of buying another vehicle to drain my time and money.

The largest diameter i want to go with is 1.5" to fit between doors and mirrors in tight clearances. I built my bumper and running board out of very thick Schedule 40 pipe, but have already dented my running boards. I need something much stronger.

The truck probably weighs about 10,000 lbs. I realize i will be adding a few hundred more pounds with the cage and am willing to deal with that to protect the truck so i can have more fun off road. I don't think .120 wall thickness 1.5" O.D. DOM tubing will be strong enough. I don't plan to roll upside down, but it is likely i will lay the truck on its side and will definitely brush against dirt banks and rock walls.

Will DOM be strong enough or must i use Chromoly? What wall thickness does the tubing need to be? Any suggestions on which directions hoops should go? I plan to add small buttresses to help brace around welds. I will weld 3 vertical bars on each running board, at least 2 points from the rear bumper, and still make the front bumper separable.

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