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S&W Racecars 10-pt cage kit

From 1984 Ford Bronco “Casual Mudder” — documented by Randy Zrubek.

73 photos
1984 Ford Bronco - 12 pieces of the S&W 10-point cage kit. 1-5/8"x0.134" wall mild steel tubing, cost $220+shpg.12 pieces of the S&W 10-point cage kit. 1-5/8"x0.134" wall mild steel tubing, cost $220+shpg. Owner 1984 Ford Bronco - I used a chop saw to cut the tubing. Some items need triming. I also used a handheld grinder to notch any ends.I used a chop saw to cut the tubing. Some items need triming. I also used a handheld grinder to notch any ends. Owner 1984 Ford Bronco - First remove seats, seatbelt anchors, console, stereo amps, CB, etc. Found $2.59 in change!First remove seats, seatbelt anchors, console, stereo amps, CB, etc. Found $2.59 in change! Owner 1984 Ford Bronco - After pulling up carpet, check floorpan for cracks or rust. Good shape here.After pulling up carpet, check floorpan for cracks or rust. Good shape here. Owner 1984 Ford Bronco - A non-poisonous snake has round eyes, but you have to get close to see them!A non-poisonous snake has round eyes, but you have to get close to see them! Owner 1984 Ford Bronco - Main hoop mounting location after checking clearance with seat.Main hoop mounting location after checking clearance with seat. Owner 1984 Ford Bronco - floor plate for main hoop. The seatbelt assly is coming out, just left it in to show location of plate.floor plate for main hoop. The seatbelt assly is coming out, just left it in to show location of plate. Owner 1984 Ford Bronco - 1/8" floor plate bent to fit contour of floor. I used a BFH & a vise.1/8" floor plate bent to fit contour of floor. I used a BFH & a vise. Owner 1984 Ford Bronco - Tack-welding seat crossmbr, to main hoop. The fit was real close, so done before mounting the hoop in the Bronco. This made the hoop legs d…Tack-welding seat crossmbr, to main hoop. The fit was real close, so done before mounting the hoop in the Bronco. This made the hoop legs d… Owner 1984 Ford Bronco - I used an engine hoist to spread the legs of the main hoop. Completed the welds after measuring and checking square w/ main hoop.I used an engine hoist to spread the legs of the main hoop. Completed the welds after measuring and checking square w/ main hoop. Owner 1984 Ford Bronco - Finished the welds with a grinder, then shot some grey primer on the seams.Finished the welds with a grinder, then shot some grey primer on the seams. Owner 1984 Ford Bronco - Tack weld main hoop legs to floor plate, after tacking plate to floor.Tack weld main hoop legs to floor plate, after tacking plate to floor. Owner 1984 Ford Bronco - Main hoop & seat crossmember mounted to floor plates.Still need to mount the frame supports.Main hoop & seat crossmember mounted to floor plates.Still need to mount the frame supports. Owner 1984 Ford Bronco - mounting frame support. The 2 black lines are the frame location, 1" under the floor.mounting frame support. The 2 black lines are the frame location, 1" under the floor. Owner 1984 Ford Bronco - Underside view of body mount support structure. The main hoop is located above floor along this line. Not much room to tie it into the fram…Underside view of body mount support structure. The main hoop is located above floor along this line. Not much room to tie it into the fram… Owner 1984 Ford Bronco - mounting frame support to main hoop. PLan to use a large 1/4" thick plate to strengthen floor (sound matt is the template).mounting frame support to main hoop. PLan to use a large 1/4" thick plate to strengthen floor (sound matt is the template). Owner 1984 Ford Bronco - I used rope and braces to hold up the roof hoop while fitting it to main hoop. Take your time with this step!I used rope and braces to hold up the roof hoop while fitting it to main hoop. Take your time with this step! Owner 1984 Ford Bronco - Notching the ends of the roof hoop to mount to the main hoop. (I did this before tying it up to the cab.)Notching the ends of the roof hoop to mount to the main hoop. (I did this before tying it up to the cab.) Owner 1984 Ford Bronco - Tie the roof hoop up with rope and support with braces. This gives you all the time to locate it in the best position, and fit the ends to…Tie the roof hoop up with rope and support with braces. This gives you all the time to locate it in the best position, and fit the ends to… Owner 1984 Ford Bronco - Fitting the roof hoop. I did this task alone, but it's better to have help with this stepFitting the roof hoop. I did this task alone, but it's better to have help with this step Owner 1984 Ford Bronco - Measure & fit the windshield post runner. Carefully measure the length before cutting. Notched the top end.Measure & fit the windshield post runner. Carefully measure the length before cutting. Notched the top end. Owner 1984 Ford Bronco - floor plates for windshield post runners, or front downbars next to dash.floor plates for windshield post runners, or front downbars next to dash. Owner 1984 Ford Bronco - location of front runner floor plate. This will be tied into the frame later with a plate and tubing underneath.location of front runner floor plate. This will be tied into the frame later with a plate and tubing underneath. Owner 1984 Ford Bronco - Miller 210 mig welder used to weld cage kitMiller 210 mig welder used to weld cage kit Owner 1984 Ford Bronco - Tack weld frame support to main hoopTack weld frame support to main hoop Owner 1984 Ford Bronco - Frame supports tacked to steel plate, welded to the floor.Frame supports tacked to steel plate, welded to the floor. Owner 1984 Ford Bronco - Tacking roof hoop to main hoopTacking roof hoop to main hoop Owner 1984 Ford Bronco - Welding frame support to floor plateWelding frame support to floor plate Owner 1984 Ford Bronco - Welding frame support to floor plateWelding frame support to floor plate Owner 1984 Ford Bronco - Welding front post runner to roof hoopWelding front post runner to roof hoop Owner 1984 Ford Bronco - Welding front post runner to roof hoopWelding front post runner to roof hoop Owner 1984 Ford Bronco - Welding front post runner to roof hoopWelding front post runner to roof hoop Owner 1984 Ford Bronco - Welding front post runner to floor plateWelding front post runner to floor plate Owner 1984 Ford Bronco - Welding front post runner to floor plateWelding front post runner to floor plate Owner 1984 Ford Bronco - Welding front post runner to roof hoopWelding front post runner to roof hoop Owner 1984 Ford Bronco - Welding front post runner to roof hoopWelding front post runner to roof hoop Owner 1984 Ford Bronco - Door brace welded to main hoopDoor brace welded to main hoop Owner 1984 Ford Bronco - Door brace and dash bar mounted to front post runnerDoor brace and dash bar mounted to front post runner Owner 1984 Ford Bronco - Door brace and dash bar welded to front post runnerDoor brace and dash bar welded to front post runner Owner 1984 Ford Bronco - Door brace and dash bar welded to front post runnerDoor brace and dash bar welded to front post runner Owner 1984 Ford Bronco - cab portion of cagecab portion of cage Owner 1984 Ford Bronco - cab portion of cage kitcab portion of cage kit Owner 1984 Ford Bronco - cab portion of cage kitcab portion of cage kit Owner 1984 Ford Bronco - Ford rear leaf spring poly bushings to be used for cage-to-frame mountsFord rear leaf spring poly bushings to be used for cage-to-frame mounts Owner 1984 Ford Bronco - borrowed a tube bender to fab the under-cab frame runnersborrowed a tube bender to fab the under-cab frame runners Owner 1984 Ford Bronco - tubing for the frame runners, to be cut to length. Also cut some plates for these and to tie the cage to the B-piilars inside the cab.tubing for the frame runners, to be cut to length. Also cut some plates for these and to tie the cage to the B-piilars inside the cab. Owner 1984 Ford Bronco - drilling 1/2" holes for bolts to attach lower plate.drilling 1/2" holes for bolts to attach lower plate. Owner 1984 Ford Bronco - lower plate for cage-to-frame runnerlower plate for cage-to-frame runner Owner 1984 Ford Bronco - Cutting the tubing on a chop saw.Cutting the tubing on a chop saw. Owner 1984 Ford Bronco - custom-made cage-frame mount.custom-made cage-frame mount. Owner 1984 Ford Bronco - custom-made cage-frame mountcustom-made cage-frame mount Owner 1984 Ford Bronco - A-pillar cage-frame mount attached to frame. The bracket for the extended radius arm interefered with a straight mount, so I used the body…A-pillar cage-frame mount attached to frame. The bracket for the extended radius arm interefered with a straight mount, so I used the body… Owner 1984 Ford Bronco - A-piilar cage-frame mount. This is for the windshield post runner from above. Custom bushing mount to frame.A-piilar cage-frame mount. This is for the windshield post runner from above. Custom bushing mount to frame. Owner 1984 Ford Bronco - A-pillar mounts (L) and B-pillar mounts (R)A-pillar mounts (L) and B-pillar mounts (R) Owner 1984 Ford Bronco - A-pillar mounts (top) and B-pillar mounts (bottom)A-pillar mounts (top) and B-pillar mounts (bottom) Owner 1984 Ford Bronco - crossmembers for mounting seats to the cage.crossmembers for mounting seats to the cage. Owner 1984 Ford Bronco - crossmembers for mounting seats to the cage.crossmembers for mounting seats to the cage. Owner 1984 Ford Bronco - 10-pt cage in blue, family bar in red10-pt cage in blue, family bar in red Owner 1984 Ford Bronco - Cage cut into 2 parts to remove for final welding; painting with 2 coats of Rustoleum "Hammered"Cage cut into 2 parts to remove for final welding; painting with 2 coats of Rustoleum "Hammered" Owner 1984 Ford Bronco - Showing 2 pieces of cab part of cageShowing 2 pieces of cab part of cage Owner 1984 Ford Bronco - Rustoleum "Hammered" in silver applied with a brushRustoleum "Hammered" in silver applied with a brush Owner 1984 Ford Bronco - A metal roll cage assembly is shown, resting on a blue tarp and supported by wooden beams.A metal roll cage assembly is shown, resting on a blue tarp and supported by wooden beams. AI caption 1984 Ford Bronco - A silver roll cage is assembled and supported by wooden sawhorses in a cluttered garage setting.A silver roll cage is assembled and supported by wooden sawhorses in a cluttered garage setting. AI caption 1984 Ford Bronco - cab section re-installed. See bronconine.com for tech articlecab section re-installed. See bronconine.com for tech article Owner 1984 Ford Bronco - Interior view of a blue 1984 Ford Bronco a roll cage and racing seat.Interior view of a blue 1984 Ford Bronco a roll cage and racing seat. AI caption 1984 Ford Bronco - Interior view of a blue vehicle, likely from the early 1980s, fitted with a roll cage.Interior view of a blue vehicle, likely from the early 1980s, fitted with a roll cage. AI caption 1984 Ford Bronco - A custom roll cage is installed inside the vehicle, with a view of the door panel and interior.A custom roll cage is installed inside the vehicle, with a view of the door panel and interior. AI caption 1984 Ford Bronco - The interior of a blue vehicle shows a roll cage and wood-grain trim on the dashboard.The interior of a blue vehicle shows a roll cage and wood-grain trim on the dashboard. AI caption 1984 Ford Bronco - Mounting rear support brace to main hoopMounting rear support brace to main hoop Owner 1984 Ford Bronco - Rear supports ( kickers) mountedRear supports ( kickers) mounted Owner 1984 Ford Bronco - Rollcage done!!!Rollcage done!!! Owner 1984 Ford Bronco - Rollcage done!!! PRP Seats installed.Rollcage done!!! PRP Seats installed. Owner 1984 Ford Bronco - Rolcage done!!! PRP Seats installed.Rolcage done!!! PRP Seats installed. Owner