Thank you for the compliments. It's nice to see people interested in building their own cages. You figure spending money on tools vs. a POS aftermarket cage, with a little learning curve, you can build tons of projects for years to come and save a ton of money at that. This cage will cost me approx. ~$240.00 and it's DOM material.

If I were just starting out and had to buy tools up front, for the DIY'er I would suggest:

-Bender: JD Squared
Get the Model 3 and appropriate Die.
-Get a air/hydraulic bracket and ram for your bender: Copperhead Fabrication This isn't mandatory but if you have ever tried to bend tubing manually while trying to be accurate at the same time....well it sucks. The above setup can get you hydraulic for a couple hundred bucks instead of the insanely priced hydro setups that JD and Pro Tools sell. I have the above setup and am very happy. I can hit the trigger on the air hose and watch degree wheel, etc. without effort.

-For the Notcher: JD Squared
Get the Notchmaster. You can use Lenox hole saws. I have found they are the best. I get mine at Lowe's.

-You will need a metal chop saw.

-You will need the Angle level finder or similar. I use this ALB combo from Angle Levels, Dial Levels, Degree of Bend indicators at Van Sant Enterprises, Inc.

-If you are new to bending tube, I highly. Once again, let me state HIGHLY recommend a tube bending software program from Bendtech. The Bendtech PRO is the best bang for the buck and even provides coping wrappers if needed. Bend-Tech PRO Download Page This software is nothing short of awesome. If you want to learn the hard way read: Pirate4x4.Com

-For specialty clamps checkout TC1 Tube Welding positioners at Van Sant Enterprises' Trick Tools.com Trick tools has a lot of cool stuff. Other alignment/tightening devices I use are standard clamps, bungee cords, ratchet straps, etc.

-Assorted hand tools, angle grinder, etc, etc.

For a great source of fabrication info check out. Offroad Fabrication Network Lots of stuff to learn there.

I am sure there is a ton of stuff I am forgetting. If you have any more questions, let me know.

Thanks again.


EDIT: For the tube clamps for the front of the cage.

Summit Machine - Products and Custom Parts

you mentioned the bender, the notcher, and the clamps
what about the welder and the plasma cutter
i'd like to get me a basic set up
what'd you suggest, great write by the way
thanks

For the welder, whatever you do, get a 240v machine. You can really only affectively MIG (gas) up to approx. 1/8" with a 120v machine (and it will struggle BTW, duty cycle). If you decide to weld thicker you will have to flux core (gasless) which will only be good to approx. ~1/4". I do not like welding flux core. It is a little more forgiving (in terms of metal preparation) ; you can get away with a little dirtier joint, but lays a sloppier bead, not to mention you have to clean the crap off afterwards. You can lay down smooth welds in MIG process with a clean joint. If you don't get a 240v machine at first and go with a 120, you will outgrow it in no time flat. The only time I ever use a 120v welder is to weld sheet metal. Don't cheap out on the welder. Get a good one and keep it for a long time.

My favorite machine for this type of stuff (off-road projects) is the Miller Millermatic MM180. This machine will easily MIG 1/4" in one pass and flux even bigger. Hobart is also a rebadged Miller with slight variations in terms of material type of certain internal parts. I hear they are good welders. A little cheaper with good performance. I believe their comparable model is the Hobart Handler series HH187 (don't quote me on that, trying to go by memory). I would recommend either of these two welders. You can't go wrong with either based on experience and hearsay.


For a decent affordable plasma cutter, reference this thread: Plasma Cutters, Plasma/TIG/Stick Combos (NOW AFFORDABLE!) - Pirate4x4.Com Bulletin Board

Most guys are running their 40 amp machine and having great results. I stepped it up to their 60 amp plasma and can draw on 1/2" plate, no problem. Either way, you won't find a cheaper plasma that performs as good as this one does. I have had mine for 2 years now with no problems and it cuts straight. During this time I have used the hell out of it as well. Best $600.00 I ever spent. The 40 amp models are a lot cheaper than that! Granted they are Chinese made, but Parker offers a warranty. A Great bang for the buck. Brand name plasmas are going for up to 3-4 times more than the Parker.

Rickyrzr, where do you get those slugs to connect the bars together, going to build new cage but need those slugs.
HAP

These?

Summit Machine - Products and Custom Parts

Let me know if this isn't what you are looking for.

yes all the tools recomended are the ones i use also. its great to build stuff yourself and spend the money in tools.

great looking RZR keep up the custo fab work.

i also watch OFN, and Pirate, some of the best info i have found on the net has been from these sites.

keep burning the wire and have fun.

Miller Millermatic MM180.

Got one, I never welded before and with a little practice I can weld. Not professional looking, but getting better by the day.

Excellent machine!

Which die sizes do you use 5.5 or 6.5?

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Thats some good work give us a wieght when you are finished.

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Using a 5.5. I always get the smallest radius I can for a given die size.

Thanks! Will do.

Finally was able to get some work done on this thing. I have been extremely busy lately. Sorry for the delay.

Will have more updated as the week goes on. This Mutha is getting finished this week!!!!!!!!!