Okay, I've tried doing my homework on this one, and I've learned some things, but am still looking for more. I want a ROLL bar, not a light bar for my 83 pickup. The intent is not to keep my truck from receiving damage, but to prevent injury to those riding in the cab and in two seats that I will be installing in the bed (bolted down and with seat belts). I've always put safety first, security second, and then performance (overall and off-raod) third.

I've heard that the suggested metal is mild steel or better (1010?) and the size 1.75 x .120. This is not a strict rule, but a good guideline.

Question A: Would this be a good, minimum guideline?

Secondly, I was considering welding not to the sheet metal on the bed, but on the metal cross members that go width wise across the bottom of the bed. Upon research this doesn't sound like a popular idea. I've heard different ways of doing so. One is to mount straight to the frame, which is strongest, but I've heard this may lead to fatigue on both roll bar and frame and also inhibits articulation by limiting frame bending (not permemant bending, but natural). The other idea I've heard is that a good bar mount is on top of the body mounts. This directs any weight (upon flip) to the frame, but isn't bolted directly to it, reducing fatigue and allowing minor sliping, sliding, movement between the bar and frame.

Question B: Would the "weld on top of the body mounts" idea me acceptable? I would like to avoid damage to my truck in case of roll over, but my goal is to be safe. If I bend a thing or two; mounts, bed's, roll bars, and welds can be replaced, passengers cannot.

I've planned a nice roll bar/cargo rack setup that I'm hoping will work, but I'm tring to research what I'm doing before I dive in without knowing what the heck's going on.

This is much apprecaited, I've been sketching/planning this thing for a few months, and after I get a water pump issue taken care of this is the first upgrade/investment I'm making on my rig.

Again, thank you for any advice.

Toyota frames are fairly stiff, I would not worry about the increased frame rigidity affecting articulation. Less frame flex is actually a good thing. There is no problem with mounting to the frame either, although it does make the cage much more permanent and difficult to mount.



I think that this is a good option. If you don't like where the body mounts are you could even add this kit from MORE. I have an All-Pro interior cage and it mounts over the cab mounts, however it does take up a significant amount of interior space. I figured it was a small price to pay for safety.