5231 YJ FRONT CAGE KIT Version 1.1

Transcription

1 POLY PERFORMANCE MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA (805) YJ FRONT CAGE KIT Version 1.1 GENERAL NOTES: These instructions are also available on our website; Check the website before you begin for any updated instructions and additional photos for your reference. Fully read through instructions prior to beginning installation. This is a weld in roll cage kit, all welding should be performed by an experienced welder with proper welding equipment Use in conjunction with PPM-5232; YJ rear cage kit. Also, PPM-5233 YJ Side Cage Kit This kit works with either a soft top or hard top Use extreme care when welding and grinding in the interior of your Jeep, remove or cover any components you do not want welding spatter or grinding sparks to damage. 1) Remove the hard or soft top. 2) Remove the roll cage padding / covers and the rear upper seat belt mounting bolts. It is also a good idea to remove the rear seat to prevent damage from welding and ease installation. 3) Install the PPM-5232 YJ Rear Cage kit per the instructions included with the rear cage kit. 4) Begin by removing the windshield supports on the driver side. Remove the T-50 bolt on the B-pillar and the 2 T-40 bolts at the windshield. See pics below.

2 5) Next, remove the inner T-40 bolt on the lower windshield bracket as well.

3 6) Next, clean up areas that will be welded. Clean up the area around the bung for the windshield support tubes. Also, clean up the surface where the top supports will be installed. See pics below.

4 7) Begin installation of the new cage by first tacking the A-pillar Sleeves into the A-pillar Floor Tubes. Push the sleeves halfway into the bent side of the floor tubes so there is 3 of sleeve sticking out of the tube.

5 8) With sleeve tacked in place, A-pillar fitment can begin. Note that the bottom of the are cut at an angle and are L&R specific; be sure to install the correct one on the drivers side. a. Next, fit the A-pillar Top tube over the sleeve. b. Place the cage base plate in the approximate area where the A-pillar strikes the floor. See pic 8.1b & 8.2b c. Fit the A-pillar assembly into the Jeep. The notch on the A-pillar top tube should just cover the bung for the windshield support tubes. See pic 8.1c

6 Picture 8.1b Picture 8.2b

7 Picture 8.1c 9) A few key notes to aide in installation: a. Place a ¼ thick spacer between the dash and the A-pillar floor tube to properly space the roll cage from the dash. See pic 9.1a b. Dbl check that A-pillar is perpendicular with the ground / jeep. See pic 9.1a c. Level the A-pillar top tube to the tub rail. See pic 9.1c d. Center A-pillar floor tube on cage base plate before tacking into place. Drawing a 1.75 diameter circle on the center of the plate will make this easier to fit quickly.

8 Picture 9.1a

9 Picture 9.1c 10) Once fitted, place a single tack on each end of the A-pillar to hold it in place. Do not fully weld anything until all cage pieces have been fitted. Repeat steps 1 through 10 on the passenger side. 11) With both A-pillars tacked in place, fit the Dash bar in place. a. Space dash bar up approximately ½ from top of dash. The tube should intersect the splice in the A-pillars. b. Level dash bar to top of dash or body of the Jeep. Take a step back and make sure it looks correct. The dash will not always be perfectly level to the rest of the Jeep. See Pic 11.1b c. It will be helpful to use a ratchet strap around the A-pillars to clamp this tube in place. DO NOT tack weld the dash bar until you fully weld the A- pillar splice.

10 Picture 11.1b 12) Next, fit the Top A-Pillar Cross Bar in place in addition to the Top Spreader Tubes. a. The bend in the spreader tubes goes towards the front of the Jeep. b. The Top A-pillar cross tube is notched at a slight angle to match the A-pillar angle. Be sure to orient this correctly. c. Use a pair of ratchet straps or some clamps as shown to square the cross tube and position it in the proper place for the spreader tubes to fit correctly. See pic 12.1c d. The top spreader tubes spacing is up to the installer, however to match the rear cage kit, they should be spaced approximately 10 apart on center. See pic 12.1d

11 Picture 12.1c Picture 12.1d

12 13) Mount the A-pillar windshield brackets to the windshield using the stock bolts. Position the bracket so the bottom and top edges touch the A-pillar. Do not tack at this time. 14) At this point dbl check that all tubes are aligned, and square or level. Tack weld all of the joints in this order: a. Lower A-pillar to floor plate b. A-pillar splice over dash c. Windshield cross tube to A-pillar d. Spreader tubes to windshield and B-pillar tubes e. Windshield brackets to A-pillars f. Again, DO NOT tack weld dash bar in place until you completely weld the A-pillar splice. 15) Drill the cage base plate holes and bolt cage to floor. 16) Weld the A-pillar splice completely, then tack the dash bar in place, again level the tube to the vehicle. 17) Weld the rest of the joints of the cage and weld the windshield bracket to the A- pillar.

13 18) Position the grab handles as shown below and weld into place. 19) At this point, cage installation is complete. Paint cage desired color to prevent rusting. It is strongly recommended to install PPM-5205 Cage Tie in Kit to fully reinforce the cage. If doing so, follow the instructions included in that kit for added strength and safety.

14 Complete install including PPM-5232 YJ Rear Cage kit and PPM-5233 YJ Side Cage Kit