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Old 03-31-2020, 11:45 PM
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EL VASCO EL VASCO is offline
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Toyota Hilux Exo Cage

OK guys here a project that started some years ago and due some different reason was delayed up to these days.

Thanks we must stay at home due to coronavirus pandemic I use this time as an opportunity to spend some hours at Bend Tech and draw some structure for the Hilux.

I had a hard time trying to find some starting pick point to start from somewhere, the best way I found was to mark two points at front and two at back on the ground using a plumb at the external edge of the tubes where rock slider will go, which ones are already welded to the chassis, that was my first reference.

Then using some leftover tubes attached to the body with some magnets and a measure tape I was taking some numbers, maybe this was the worst part because you need to think it in a tridimensional way (X, Y, Z)

Main hoop was the easy part, I've made some of them and it has all 4 bends in the same plane so not too much problem.

First attempt of front hoop was not so bad considering it has 4 bend at different planes but I really didn't like how it turns out, too much space between the tube and the fender, where then should go the A pillar if I'm not wrong with the name of that part, so half stick of material lose, no problem I took it as practice and learning.

I made another front hoop with a different design with a closer angle at the fender and on last bend I confuse de rotation so well another half stick gone, I guess the art of bending tube is not so easy hahaha

3rd attempt was fine only that I think I have something wrong with my Pro Tools 105HD bender because I get one leg some degrees out of plane respect to the opposite leg and the entire hoop came out just a little bit narrow than I wanted it so I just split it in half, sleeve it with an internal tube and then with a small piece of the external diameter to give the hoop the width I wanted, welded it all together, some cosmetic flapping and I could solve the mistake.

OK let's go to the pictures, hope they work, I was posting some pictures to test the other day and they appear and disappear, don?t know really why, so here we go

First attempt front hoop

[IMG]IMG_20200317_164448 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200317_164526 by El Vasco, en Flickr[/IMG]

3rd attempt

[IMG]IMG_20200325_185101 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_191003 by El Vasco, en Flickr[/IMG]
IMG_20200325_191932 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_192303 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_192506 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_193608 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_193843 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_194914 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_195259 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200325_200239 by El Vasco, en Flickr[/IMG]





Here one leg a couple of degrees off

[IMG]IMG_20200326_105638 by El Vasco, en Flickr[/IMG]

Last edited by EL VASCO; 04-02-2020 at 11:38 PM.
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Old 04-01-2020, 12:00 AM
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EL VASCO EL VASCO is offline
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Solving the offset leg

[IMG]IMG_20200326_111526 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_113738 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_162858 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200330_165918 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_175828 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_175931 by El Vasco, en Flickr[/IMG]


Testing A pillar, is correct the name of this part??

[IMG]IMG_20200326_191847 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_192146 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200326_192212 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200331_181938 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200331_182013 by El Vasco, en Flickr[/IMG]

Last edited by EL VASCO; 04-02-2020 at 11:51 PM.
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Old 04-01-2020, 12:36 AM
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Not seeing pics...
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Old 04-01-2020, 02:22 AM
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Odd, pics ar OK in post one.
But ? in post two.
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Old 04-01-2020, 09:14 PM
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Well this is a shame if you can't see the pictures, I can see them all on phone and computer.

Some progress from today

Tack weld A pillars in site and start figuring out a top cross member to join A pillar and an inverted "V" shape to connect that top cross member with front hoop

Hope you can see the pictures

[IMG]IMG_20200401_140234 by El Vasco, en Flickr[/IMG]

[IMG]EFFECTS by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200401_155855 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200401_155904 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200401_163057 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200401_165357 by El Vasco, en Flickr[/IMG]


Would like to get some feedback, what do you think, any comments welcome

Last edited by EL VASCO; 04-02-2020 at 11:58 PM.
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Old 04-02-2020, 09:50 AM
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I'd love to see them as well, but am only seeing a minus sign in a circle for the pics
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Old 04-02-2020, 12:13 PM
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All the pics are gone again.
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Old 04-02-2020, 03:22 PM
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Quote:
Originally Posted by Maxx Levell View Post
I'd love to see them as well, but am only seeing a minus sign in a circle for the pics
Same here. Based on the URL they seem to be hosted on a google platform but I don't know if it is allowing sharing.

Hope you can figure it out because I'd also love to see!
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Old 04-02-2020, 09:59 PM
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OK guys it's a little bit frustrating what is happening with pictures here, you are right today morning I saw the imagine with the minus sing and now I can see all the pictures again perfectly

So going to create a Flickr account right now and hope it be the solution, let me see if I can do it right
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Old 04-03-2020, 12:12 AM
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I think pictures should show now, took me a couple of hours upload all pictures to Flickr the host many of you use here so hope you can see some action now

Progress from today, tack weld top cross member to the A pillar, inverted V shape and start making some cross member to reinforcement on roof, sorry I know parts I name maybe are not its correct name, feel free to correct me please

[IMG]IMG_20200402_123745 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200402_141935 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200402_142418 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200402_142644 by El Vasco, en Flickr[/IMG]
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Old 04-03-2020, 03:17 AM
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See, Google IS evil!
Flickr is a bit of a nuisance to use but they are not stealing your pics.
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Old 04-03-2020, 11:23 PM
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Quote:
Originally Posted by R3Fab. View Post
See, Google IS evil!
Flickr is a bit of a nuisance to use but they are not stealing your pics.
Great you can see pictures now, hope everybody here can see the pictures too.

Some from today, prepare the tubes to form X shape on roof, I know I draw/designed my front and rear hoops on Bend Tech and have pretty close all dimensions very defined so I could keep making the hole assembly on Bend Tech but for some reason I'm not feel very confidence to do that so I made it by eyeballing and of course lot of work, lot of go up and down stairs to check, lots of grinder but at the end of the day I got almost ready on the cross member roof, some rain finished my work day leaving two more fish mouth to do

[IMG]IMG_20200403_145010 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200403_145221 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200403_145510 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200403_185224 by El Vasco, en Flickr[/IMG]

[IMG]IMG_20200403_185204 by El Vasco, en Flickr[/IMG]

Home made center line finder, very useful when you work old school way

[IMG]IMG_20200403_132119 by El Vasco, en Flickr[/IMG]
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Old 04-04-2020, 08:34 AM
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I can see all the pics now. Thanks.
Nice work.
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Old 04-08-2020, 12:08 PM
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Quote:
Originally Posted by alwaysFlOoReD View Post
I can see all the pics now. Thanks.
Nice work.
Agreed!
Thank You.

E
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Old 05-13-2020, 11:59 AM
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The pictures are working for me now also. Looks like it's coming together nicely! I agree it's very hard to measure outside dimensions for something like this. Because of this, I built my exo one side at a time, then added the cross bars and over-cab X brace. You can find my build thread/photos here in case any of it helps: https://www.offroadfabnet.com/forums...ead.php?t=1118 After I sold my 4runner, a future owner made good use of the cage and it has survived a number of flops, but I think if you want good rollover protection you really need an X brace for the main hoop and you might even consider tying the whole thing into the cab.

Look forward to seeing how it progresses. I like exocages when they are done tastefully. I may have to put one on my Nova to maximize cabin space.
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Old 05-14-2020, 11:50 PM
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Thanks Bandit for your comments and of course I?ve seen your thread build some years back when I was searching for ideas, it was a great inspiration by the way. If I?m not wrong your choice of tube was 1-3/4 x .120 wall HREW right?? I mean you just used HREW instead of DOM tubing; because this is my choice here too, you know here if you want DOM you have to make a special order and it?s really expensive compared with HREW, and yes I know the differences between them.


So I keep working on the Toyota Exo Cage some days at the week and when weather allows it to me and as we are still in quarantine so we are slowly coming back to ?normal life? too too slowly for our economy , not so good.


As I mention before this project started some years ago so first thing to do was an internal rear hoop, see pictures, and because this truck had a roll over and the body was damaged and using it as an advantage the owner wanted it to looks like a mix between a Tacoma and an extra cab so the idea was to do that internal rear hoop to have some point where to cut the rear portion of the cab and close it with sheet metal, this was done for the owner.


OK some more progress pictures


Here you can see the internal main hoop, it needs some more tubes but you get the idea, then both hoops, the outside and the inside will be sandwiched


IMG_20200513_142514 by El Vasco, en Flickr

Here some of the X brace on the roof

IMG_20200404_122540 by El Vasco, en Flickr



IMG_20200404_122608 by El Vasco, en Flickr

IMG_20200404_122650 by El Vasco, en Flickr
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Old 05-14-2020, 11:59 PM
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Starting with the rear cage

IMG_20200410_103449 by El Vasco, en Flickr

IMG_20200411_105932 by El Vasco, en Flickr

IMG_20200411_150511 by El Vasco, en Flickr

IMG_20200421_185509 by El Vasco, en Flickr

IMG_20200421_185526 by El Vasco, en Flickr

IMG_20200421_185539 by El Vasco, en Flickr

http://IMG_20200513_142834 by El Vasco, en Flickr
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Old 05-15-2020, 12:46 PM
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Quote:
Originally Posted by EL VASCO View Post
If I?m not wrong your choice of tube was 1-3/4 x .120 wall HREW right?? I mean you just used HREW instead of DOM tubing
Yes at the time HREW was all I could afford and I did used 1-3/4 x 0.120. That cage was really unfinished when I sold the truck - it had no cross bar under the window, no upper fender bars, and no X brace at the B hoop, etc. With all those missing elements, I suspect it would not survive well in a rollover or endover. It was a good start though and it did get used by the future owner; he put the truck on its side at least twice that I know of before he cut up the back of the truck and added a rear cage section. There are more recent photos of the truck here: https://www.pirate4x4.com/forum/toyo...ld-thread.html

There is a good deal of debate about HREW vs DOM, but the design of the cage itself is where I think people should focus their discussion. In my armchair expert opinion the primary design flaws I've seen are (1) inadequate lower frame/body attachment leading to the cage "poking through" or collapsing down (2) inadequate cross bracing leading to the cage bending off to one side and (3) long unsupported lengths of tubing that end up buckling.

It looks like you've addressed most of those issues. The only area of your cage that concerns me is the lower mounting of the A pillar. It looks like it's attached to a single piece of tubing that's cantilevered out from the frame. If the truck has an end-over roll and lands on the upper window bar, the A pillar tubes may push down and simply bend the cantilevered tube away from the frame. Maybe if you add more frame attachment points for the rock sliders, that will help support the A pillar and it would be less of a concern.

Look forward to seeing more. I love exocages.
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Old 05-15-2020, 07:08 PM
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Yes you are right about the debate about HREW or DOM, I?ve read this a lot of times but for me as you say it has a lot to do about design, you know some years ago I had the chance to spoke with an old man, an old school man, of whom I have a lot of confidence, and he told just that, the importance about design is critical, a good triangulation, and if you get that goal well done you even could use small diameter tube saving some weight

As a side note I know that if you are planning to build a race truck or car well so you should go with the rules of that category and DOM tube or Chromo Moly tube would surely be the choice of material, but when it comes to a recreational rig with slow speeds I think a HREW well-designed could be fine.

About the lower mounting point of A pillar I still need to add one more reinforcement tube or maybe two connecting the chassis to the rock slider, yes sir.


Some front side pictures

IMG_20200412_123410 by El Vasco, en Flickr

IMG_20200412_123432 by El Vasco, en Flickr

IMG_20200414_172949 by El Vasco, en Flickr

IMG_20200414_173012 by El Vasco, en Flickr

IMG_20200513_142652 by El Vasco, en Flickr

IMG_20200513_142810 by El Vasco, en Flickr

IMG_20200514_182648 by El Vasco, en Flickr

IMG_20200514_182727 by El Vasco, en Flickr

IMG_20200514_182758 by El Vasco, en Flickr

http://IMG_20200514_182844 by El Vasco, en Flickr
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Old 05-15-2020, 07:11 PM
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Nice progress!
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