Needed something to take my mind off things, so I started working on an exocage for my 4Runner.



First I bent the two B pillars, but I forgot about the camera until they were already done, so let's start with the two A-pillars (below).



(Below) Here I am fitting one of the A-pillars.



(Below) The cage is 1-3/4x0.120. At the back of each A-pillar, I inserted some 1-1/2x0.095 tubing and plug welded it in three places around the tube. Later I will build the back half of the cage starting from these splices.





(Below) Cleanin' up the plug welds with a pearl pad.



(Below) Lots of welding and fitting.









[img]http://thebandit.xtremefabricator.com/exo/exo12.jpg[/img]

(Below) While I don't encourage it, I used a wet towel while welding to keep spatter off the windshield and body.

[img]http://thebandit.xtremefabricator.com/exo/exo13.jpg[/img]

(Below) My welds aren't spectacular, but they should hold fine.

[img]http://thebandit.xtremefabricator.com/exo/exo14.jpg[/img]

[img]http://thebandit.xtremefabricator.com/exo/exo15.jpg[/img]

[img]http://thebandit.xtremefabricator.com/exo/exo16.jpg[/img]

That's as far as I got this weekend. I should mention that while I welded as much as I could on the two cross braces, the A & B pillars are only tack welded at the bottom. When I am done doing the cross bracing, I'll break those tacks and pull the whole thing off to finish welding all the backsides.

I'll take some daytime pictures later this week. Depending on when my treatment starts, I'll pick up on this project again in two weeks.

*EDIT* Daytime pictures added

[img]http://thebandit.xtremefabricator.com/exo/exo17.jpg[/img]

[img]http://thebandit.xtremefabricator.com/exo/exo18.jpg[/img]

[img]http://thebandit.xtremefabricator.com/exo/exo19.jpg[/img]

[img]http://thebandit.xtremefabricator.com/exo/exo20.jpg[/img]

I got a chance to work on the cage again today, so I pulled it off again. Nevermind the rust that's accumulated over the last week.





Here's a look at some of my copes. I love [color:"DarkOrange"]Bend Tech[/color]. It's simply amazing.















First thing was first; getting rid of all the rust. I used CLR and some Scotch Brite pads. This worked INCREDIBLY well. I soaked the pads in CLR, wiped down the tube, and sprayed it off with a hose. All the rust was gone.

Next up, I started welding.... lots of welding. I am using a 110V MIG cranked up to eleven (Spintal Tap joke). My welding isn't phenominal but I'm getting better!



















Here it is with all the cross bracing welded up.



Next I emptied a can of Rustoleum Hammer finish silver on all the upper tubes.

[img]http://thebandit.xtremefabricator.com/exo/exo47.jpg[/img]

When I have time again I will weld this onto the truck and get to work on the upper fender bars and cowl tube. I haven't decided yet how I want to do those, but I've got a few ideas.

sick doode. are you planning on extending the cage over the back of the truck or not?

Looks really good, particularly the fitment between tubes. I think that your welds look good too, as you know it takes a lot of practice to lay down perfect beads.

Are you going to add another bar from the front bumper to the A pillar at the top of the fender?

How are you cutting your tubes?
What's the weight of the exo?

That is really nice craftsmanship!! Have you considered taking an old truck, cutting the frame off past the cab and making a custom tubular frame like so: Ultimate Toyota Build-up

Thanks guys, good questions.

eightyeight, yes I am going to extend it to the back of the 'runner, but not for a while. I have some plans for hacking up the rear of the truck that I need to do first.

DirtyHarry, thanks for the complements. I will indeed be adding tube along the top/side of the fenders to the A pillars and a cowl cross bar.

dcg9381, I am cutting the tubes using Bend Tech software (www.bendtech.com) and an angle grinder with a cutoff wheel. I don't know the weight of the cage right now, but I can lift it by myself without too much trouble (other than it being akwardly large).

EzCruiser, I don't think I am going to go 100% tubing out back. I camp a lot with my truck and I want a fully enclosed cab/cargospace. My plans do include a custom bobb and some unique tubing, but I want to SAS before I start the rear half.

that is definetly the nicest exo i have ever seen.. good job man!!