Through the dash cage builds

[sierradmax]

All this talk about 3D scanning and CAD, I put the jeep in the shop, sat down while consuming some rocky mountain Kool aide to come up with a plan. I plan on using a form of CAD.. Cardboard Aided Design. With a couple of 4x8 sheets at my office, I think I can get the angle stenciled out on some cardboard to assist with initial bends. Let's see how it works.

Oh, I will bring some technology into the thought process.

https://www.thingiverse.com/thing:5322320

 

[Rnuovrcj5]

reviving this thread.

I'm starting to plan for the through-dash tube and I'm open to idea's on how to best tackle, getting my angles correct..

1. It looks like the tube originating from the floor and coming through the dash would be 100% plumb, or parallel to the TJ dash/perpendicular to the floor.
2. Initial bend could be at the top of the dash and mimic the angle of the windshield frame.
3. A second bend might be required to align the tube to meet the header bar, before notching.

It seems kind of difficult getting both bends & the angle of the notch in the upper tube dead nuts without some expensive trial and error. Is the upper "notch" best attacked by leaving the tube long with multiple test-fits after some careful die-grinding? Thoughts on a round tube clamp at the header bar so the entire cage can be removed without having to tear apart the dash?

Mine’s through the dash with one bend at the top of the dash and one down by the floor. A/C duct is untouched and functional. You can only barely see the a-pillar bar from outside the jeep. Getting a tube across the top of the windshield and keeping the latches for the top functional is about the worst part of a TJ cage. Mine’s tucked into the window frame above the rear view mirror and it’s TIGHT around it.