Ultimate Adventure 2007 Jeep Wrangler JK Roll Cage - UAJK

The first step in bending tube was running tube from the front to the rear. We like this cage design as it allows the Jeep to easily slide under low-hanging branches, rocks, and so on, since the same tube runs the whole distance. Also note how it is similar to the design used on the four-seat buggy in the background. Some people build a halo tube that goes around the top and then has down bars to the floor which also works just fine.

When the half-doors arrived, Paule and Errea cut down the B-pillar to match the height of the doors. We always think we're smart and spend time second guessing OEM engineers and designers, so we'll refrain from saying how goofy the B-pillar looked prior to our work with the saw.

The new cage B-pillar is welded to the inside of the body B-pillar, and the body pillar is then capped to match the body lines of the doors.

In the back we reinforced the body with 3/16-inch steel plate where the new down bars tie into the tube. The plates help spread the load of the cage should we ever go belly-up, and also gives us a solid point for welding the tubes.

We used a Hobart Handler 187 MIG-welder to install our cage. The welder is capable of up to 5/16-inch steel. This 220-volt machine is a great entry-to-midlevel machine in a small package. We used 75/25 welding gas and 0.035 wire. In addition we had two of Hobart's auto-darkening welding helmets on duty so that the welder and anyone helping him mock up tubes could be shielded from the pretty blue light.

Since we knew the Jeep was going to have a bikini top, the Twisted Customs crew decided to roll the top bars. This will hold the top higher in the center and help keep foul weather from puddling up on the top.

Finally the four front and back roof bars were installed as well as multiple gussets for additional rigidity. The cage is now stronger than factory, but the original soft top will no longer fit since the factory unit had lots of plastic brackets that tied the top into the cage. We will also be using aftermarket seatbelts and seats since the original units also tied into the cage. Come back in 30 days to see us start taking more stuff off of our brand-new Ultimate Jeep.