2016 RZR 1000 S roll cage build

[wayne86]

My wife and I had been discussing getting rid of our 800 RZR for a while now to trade up for a 900. We pretty much had our eyes set on a 900 until my brother picked up a brand new 1000s. Things are nasty compared to the 800. My wife and I both took my brother's ride for a spin and decided we had to have one too. The whole idea was that we would sell the 800 and my XJ and wheel the new 1000S until I finish my CJ5 build.
We picked up a black 2016 1000S about a month ago.

We took it home, i ripped a few donuts in the garage and parked it. The next day my wife takes it out to show the neighbor. Well, she was trying to show off and, literally, in 16 seconds she rolled it on it's side in our field trying to do a donut.

I figured we better put a cage on it before one of us goes tumbling down a hill with the newfound confidence of 100 hp under our feet. So we tore it down and went to work. We have never done any tube work. If it weren't for bendtech and a couple of friends to get us started we would still be staring at it. So here's our first attempt at building something that's functional and looks decent. Still have to do bumpers and add tabs for harnesses and brackets for the doors but we are at a good stopping point to take a break for the holiday.

I'll probably continue to post pics of our progress. Hoping to be done by the middle of January...we work slow!

Merry Christmas!

 

[wayne86]

Took us almost a month to finish the rear bumper, the front bumper, getting the harnesses in, and installing the winch. We took the cage and bumpers to get powdercoated Monday. Hope to have it all bolted in next weekend and cleaned up for a ride.

Here's how it turned out with last bit of tube and metal work.

My wife wanted to weld a little since this will mainly be her rig.

I started making templates for the aluminum panels. I have never done any fab work like this before and really enjoyed the process of finishing the roof up.

We used the edge of the welding table and some square tube as a break to bend the 1/8" aluminum skins.

I ordered these harness brackets from WOD. These should hold the PRP 5.3 harnesses in place and keep us tied down.

 

[rapidrob]

That looks great, especially for a first cage build. Congrats

 

[wayne86]

That looks great, especially for a first cage build. Congrats

Thank you! The only bending I did previously was small stinger on my XJ. If it weren't for the Bendtech software I would have probably never finished. That being said I'm ready for the next project. I have a CJ5 that needs my attention.

 

[wayne86]

Took the cage to get powder coated last monday. We got it put on Wednesday night and and the panels all bolted in place. I have to pick up some bolts to mount the harnesses and get the rig cleaned up so I can take some pictures before we take it riding. If I don't get the pics now, one of us will roll it down the hill and it will never look "new" again. My wife picked the color. I wasn't too sure about it on the color swatch but it looks pretty good in person, i think. The powder coater had a drag race frame sitting in the shop and he said our color choice sold that guy on doing the same thing. Pics to come later!

 

[wayne86]

 

[onepieceatatime]

Re:

Dude that's bad as hell and makes me wanna buy a bender and bendtech.

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[wayne86]

Thanks man! You should get a bender and the bendtech! I way underestimated myself on what I could do with the tools. I'm glad we did it ourselves. Maybe I'll run into you on the trails. I'm in Northeast Indiana just south of Ft. Wayne. Not sure where you are in Ohio.

 

[onepieceatatime]

Re:

I'm in Columbus. If you ever wanna check out some Ohio trails hit me up. Where do you ride up there?

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[wayne86]

Re:

I'm in Columbus. If you ever wanna check out some Ohio trails hit me up. Where do you ride up there?

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We go to Haspin Acres quite a bit and Attica Badlands. We usually take a trip to Windrock over the summer and one other big out of state trip. Once I get the CJ done I'd really like to go Harlan. I don't know of any places in Ohio to wheel except Wellsville area and I've heard you need to know somebody to navigate.

 

[onepieceatatime]

Re:

We're planning to go to Windrock the end of April and always go to Harlan the beginning of October. There's a few places I'm Southeastern Ohio to ride and one other really good place in North Eastern Ohio if your vehicle can kind of pass as street legal.

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[wayne86]

I would like to try to make the CJ "street legal". At least have working lights and turn signals if possible. The RZR has the registration stickers to drive on road in some counties in Indiana as long as you stay on county roads.