EASY Off-road Roll Cage... Ultimate Suzuki Samurai Build Episode 8.

Building a roll cage can get... complicated.
The tube size, placement, and even material type can be the difference between a safe roll over or a nightmare. BUT if you look at the basic rules from Ultra 4, Score or the NHRA, you can have an idea of what engineers consider safe.
In our case this Suzuki Samurai build is going to be at SEMA 2023! So, this cage needs to look good too.
Today we make some big compromises to custom tailer a roll cage for our exact application, and we even alter the body to maximize safety / comfort. This is a BIG episode with a ton of information, so I hope you enjoy it!
Huge thanks to ‪@BigTireGarage‬ and ‪@WillometMotorFab‬ for your help with the episode!
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DISCLAIMER:
Due to factors out of the control of Dirt Lifestyle, we cannot guarantee against improper use or unauthorized modifications of this information. Dirt Lifestyle assumes no liability or responsibility for property damages or injury incurred as a result of any information contained in this video. Use this information at your own risk. Dirt Lifestyle recommends safe practices when working on vehicles and/or with tools seen in this video. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Dirt Lifestyle. Be safe!
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#offroad #suzukisamurai #4x4

[@76kz400]

I chuckle every time I see the Bender sticker on your tubing bender!

[@overlandout7105]

Honest opinion: I wasn’t very interested at the beginning of this build because I’m not much of a samurai fan. But as the videos went along, I found myself heavily invested in this series now and I’m loving how this is turning out. Great video!

[@DirtLifestyle]

Understandable 👍. I'm glad you can enjoy the videos even though you aren't a zuk fan. I try to make these builds interesting to anyone! But it's tough...

[@josiahdegroot5341]

I felt the same way, learning lots but wasn’t super into dedicated rock crawlers. Now I’m in it to win it

[@afarmer1062]

Why not tie the seats in to the cage? Kinda threw me for a loop after you talked about ultra 4 spec several times.

[@roachwerks3043]

I can 2nd this. Nate really knows how to put a vehicle together

[@TrailTime.]

I’m glad you guys talked about exo cages. I’ve hated them since the moment I saw one. Ian nailed it explaining it, as always!

[@callmesomething1425]

A well planned hybrid cage works well, but like Ian said if you can't weld the whole way around its only half of a roll cage. You have to make it removable to insure you get it good enough to bet your life on.

[@TrailTime.]

I hear the argument, I just feel that too many EXO cages are done because of either laziness or lack of skill. Of course, there’s reasons to have bars outside of the body I.E. rock rails. But the moment somebody makes the decision to run bars outside they go overboard 90% of the time and think it’s going to do them good

[@KevinHalliburton]

Yes!

[@christopherhiggins5409]

Xo cages are the worst. I agree completely. You can even take a solid nice looking truck and totally ruin it with one of those things

[@DirtDogGarage]

​@@callmesomething1425 wouldn't it be easier to weld all the way around an exo. Tac all together remove weld all around and re install. Just my opinion but if u had let's say a ranger unless u can drop the cage through the floor u won't be able to weld against the cab either. In this video it's easy for him to build this cage because there is no top. But an actual internal cage in a truck is much harder to weld all the way. Plus he talks about head clearance. A ranger has a much shorter roof than that sami unless ur sitting on the floor.

[@MooreFabWorks]

Safety first! It's priority. I have built a couple monster trucks, and followed feld racing specs. Same thing you did, just different side. Lol. But egos have to go. Can't stand someone with a foolish ego. Great job and explanation! Love this video.

[@mikemorgan4670]

Awesome video Dude. Hectic and productive, really fun to watch.

[@DirtLifestyle]

Thanks, man! Unfortunately, many people think they know better. Especially if they are a recreational user and never have to pass tech inspection. But these details are life and death! Hopefully, this video will point people in the right direction.

[@MooreFabWorks]

@@DirtLifestyle for sure! I'd rather someone tell me I put a tube in a wrong spot than someone get injured or worse. I'm glad you said what you said.

[@callmesomething1425]

Dude how much of a dream come true is it to for one to be able to call Ian your friend and two have is whole knowlage base at the end of a phone call. Green with envy lol

[@DirtLifestyle]

I'm very fortunate 🙌

[@kcnicklaw1698]

I love David's tercel and suburban cool to see you bring in other bad ass builders.

[@roachwerks3043]

This is probably my favorite tube work project you’ve ever had on the channel. And seeing david was a nice surprise, I’ve been following his burb build pretty much since he started KZbin. Great super underrated channel in its own right

[@billjcanada]

Watching you draw your layout on the shop floor brought back a memory. Many years ago I had done the same thing. I was in the Navy at the time and had to take a little sea cruise. While I was gone the wife decided to help and she cleaned the floor. Thankfully I had written down my measurements in my notebook

[@billylemire5469]

As someone who was rolled off the highway in a TJ at 75 courtesy of a wrong way drunk driver, I appreciate your attention to detail with the roll cage. My TJ roll cage was tweaked sideways but still saved my life!

[@NotAMartian-1]

I rolled a TJ with the factory sport bar and snapped the main hoop right above my head, folded both rear bars over and the windshield ended up flush with the dash. The TJ factory bar is absolute garbage

[@vincewetherell8464]

Exo cage or internal cage. They can both be properly done or poorly done. A properly done XO cage can protect you and your glass. A properly done internal cage will protect you but your windows and even door function are at the mercy of the trail. Just me thinking out loud. Thumbs up to Nate and Ian thank you for being great ambassadors for our sport.

[@hombre3000]

Loving all the folks coming into the shop to lend a hand. It's great to see you delegate some of the work and see new faces. Great stuff as always, Nate! Thanks for always keeping safety in focus.

[@rorycaracciolo6814]

I dont get out of bed until 10:55 on sundays just because I dont want to do anything until I watch the new DL video, this is my church service haha

[@DirtLifestyle]

Lol thanks brother

[@RM_Garage]

Nate, we must both be using the same royalty-free music platform because I swear every time I release a video, yours comes out with the same songs! Of course yours are much better, but always cracks me up. As always, awesome video dude.

[@MonkeyMotorSport]

Very glad to hear you promoting the building of fit for purpose cages.

[@chrf65]

FINALLY someone with a known voice is saying what I have been saying for YEARS!!! Ive done a ton of different racing, Ive seen a ton of shitty cage designs, bad welds, people not fitting properly inside cages or belts etc..Improper design and set up can literally kill you. The most stringent tech Ive ever dealt with has been the SCTA..When it comes to land speed racing, those people DO NOT mess around.

[@thesneak281]

Amazing work! Well thought out nate. Always cool watching a local fabricate!

[@jiggyquinn5635]

Thank you for sharing.

[@waynecooper1676]

Screemon Deemon Fab. I have watched several videos of yours.. You Have to admit lots of envy and respect for your skill. I am working on my first build You, Ian and the late Jesse Combs have been helpful from the beginning. Thanks for the well explained and samples of the work.

[@JeepTJay6]

Amazing work! I really look forward to these episodes. Listing to you explain how and more importantly why your building things at every stage is a great value to your subscribers. Thanks for these.

[@DirtLifestyle]

Thanks man! I appreciate the positive comment 🙌

[@newtonfirefly3585]

I'm surprised more people don't wear mountain bike helmets to protect there heads from the cage incase of a rollover.

[@DirtLifestyle]

I'm going to keep helmets in this zuk for sure. I won't need them 99% of the time but on real sketchy stuff I want to keep one near by

[@tacotots_132]

It’s fairly common with dedicated rock buggy’s and such!

[@nicholascooper1193]

I like skateboard helmets. less bulky and goober looking than a mtn bike helmet

[@betoborba3329]

Open face helmets like the ones for rally cars our trail bikes work really good! That’s what I use on my utv on slow ride’s our any type of crawling! You are able to see all around with some fairly good proration!

[@punk46664]

I have a Bell one piece full face mtb helmet. Weighs less than a kilo but still certified.

[@GettinJunkDone]

Nate, you have taught me more than you ever understand. Given me inspiration to tackle a driveway build myself and I still have so much to learn, but I am no longer waiting. Thanks for all the great videos, keep up the good work my friend.

[@DirtLifestyle]

Thanks man!

[@hoganmaughan3273]

Nate, I know you harped a lot on how your Zuk's cage isn't going to be "the best looking", but man, I think the thing looks PHENOMINAL. lol Great job!

[@SandduneStepper]

Wow waiting for this vid all morning

[@DirtLifestyle]

I'm honored and I hope you enjoyed it 👍

[@Roks4life]

Cage is looking awesome! Those struggles of indecisiveness are signs of a true craftsman and someone that takes real pride in their work and understands that shortcuts are flaws.

[@christopherhiggins5409]

Nate, your show absolutely rocks. I watch it all the time. I was wondering, would you ever be able to do a video on how to design a off-road suspension as in how to design a three link or a four-link?.... Keep up the good work man. I've learned so much from your channel and I can't wait to see the end of the Suzuki build... Higgi from North Carolina

[@WalterCook-wh2ue]

I love this! As a fabricator who builds Formula Drift Spec cages, its very important to follow the rules.

[@PaulKaiser42]

It’s really looking great….the balance of performance and eye candy is great!! 👍🏻. As always awesome video. Having Dave there is awesome….I miss his fabrication videos

[@WillometMotorFab]

Hey Paul. There's a freshie on the channel, with more in the hopper.

[@PaulKaiser42]

@@WillometMotorFab that’s outstanding

[@MacsSpecialitiesMotorsports]

Holy good info here!!! I ❣Love the cage info and your cage advice!

[@basikbiker]

A tip for using the bender too...measure the ram extension when making your bends, don't base your measurements of the degree dial, it's wildly inaccurate and inconsistent if trying to repeat bends to be symmetrical

[@Wade970]

“Because Pretty Ain’t Tough!” D&C Extreme, Colorado Springs, CO.

[@JacobShepherdEngineer]

Really liked the dive into the roll cage spec. I've always wondered how people knew what to build.

[@hotshtsr20]

SFI roll cage padding is a must for anything that you can touch.

[@abnpthfdr2934]

Samurai's coming along great!!!

[@zachariahohlman7046]

This is where I’ll chime in. Having a vehicle with a “hybrid” cage. It’s the strongest and best choice of cages. Especially for a unibody vehicle. For many reasons. 1. The cage is physically welded to the body of the vehicle where it goes through the roof, so the cage and body combine to become a even more rigid structure. 2. You have way more interior head clearance for safety 3 you get to maintain a mostly stock interior 4 in the event of a rollover you don’t smash up the body of the vehicle. Important on a unibody because that’s not something you can easily replace

[@kirshberndt8412]

Congrats on SEMA! Learned a lot about exo-cages, makes sense now. 😬👍🇨🇦

[@MrBillsfishin]

The cage looks great so far and structurally very sound.

[@beadblaster9508]

Can you add the high density foam rollbar padding in areas where your head and legs may contact the roll cage. They have the half circle stick on foam.

[@alexanderadcock4962]

I have see exocages for Jeep Cherokee xj. The supports go through the body but, give you head room inside. They look good but, holes in the roof. Great information in this video.

[@MacsSpecialitiesMotorsports]

The info you and Ian from #bigtiregarage had about EXO cages, you two made some valid points and I dont think I will doing a EXO anymore on my ZJ. Thanks for the info!!

[@griffoutdoortv5882]

sammy is looking good cant wait to see it done but Im also enjoying the videos between now and then

[@jasonjohnson4214]

Build is really coming along Nate! This is a really fun series!

[@DirtLifestyle]

Thanks man!

[@The_White_Bison]

I love the fact we both live in Washington. It’s nice to feel like we could run into each other one day

[@mathewmay5361]

The cage looks Rad!! Great job. Everything is coming along very nicely!! Can't wait till next week!

[@DirtLifestyle]

Thanks!

[@ALMX5DP]

21:25 thank you for immediately answering the first question that popped into my head seeing that. Looks beautiful, cant wait to see the end result!!!

[@sgtaaronp]

I'm in for this series!

[@paulvanhouts3365]

Hi Nate, I am enjoying your practical approach and how you strive to do it right or look for info to help get there. You share valuable advice. Thank you.

[@michics100]

Been watching your build video's and it's looking good. Your discussion about whether or not you would bump your helmet into the vertical side hoop I have a suggestion you may have already thought of. Look at road racing seats. Besides lower side bolsters they also have wrap around shoulder bolsters. And these come in many degrees of wrapping. Once strapped in with a full harness the these bolsters help hold your upper torso in the center of the seat along with your head. Maybe you use your current seats for SEMA and true race seat for your rock crawling. Just a thought.

[@StormbornJKU]

It’s looking pretty darn cool

[@CPhilliPS30]

Thanks for doing this. I think your videos are making the industry better and safer.

[@DirtLifestyle]

Thanks brother, I appreciate it!

[@PNW_Rodeo]

That cage is wicked! A suggestion for the upper support off the seatbelt bar...mimic the lower arch. I'm really enjoying the collaborations and awesome fab work. Ill be patiently waiting for next weeks video. 👍

[@mnhockeyone]

Another OUTSTANDING video Nate!

[@daviddoodle87]

Lots of good points. I personally will do a hybrid with some rub bars. I'm not scared about dilling holes. 😄

[@DirtLifestyle]

Hybrid is the only way I would run an exo 👍. The hydrid cages are a nice compromise for unibody rigs, and I think they have some big benefits.

[@goodluckcult3157]

Great looking and functional cage.

[@jnkellogg737]

Love the updates on this beautiful build. I can’t wait to see it finished

[@DirtLifestyle]

Thanks!

[@JWK163]

Cage looks killer.

[@DirtLifestyle]

Thanks dude!

[@307Garage]

Looking good!!!

[@turtlecrawler]

I have a partial exo cage on my 85 4runner around the cab. The A pillers punch through the front fenders and tie into the sliders. Not ideal, I have thought about adding another tube to tie them into the frame as well. Then I have the exo B pillar that is welded to the slider. Then I have a bed rub rail running from the B piller back to to tail lights. Its bolted into the very back corner. But has 3 welded tie in points with holes through the body. I added an internal B hoop which is bolted through the body, and attached to the frame. The internal B pillar hoop is then tied into the factory cage. The rub rails are attached to the internal B piller, and 2 points on the factory cage. The exo is also pretty tight to the body. The main point of my exo to keep from cracking my windshield against a tree, or denting the cab around the door frames.

[@wesc4054]

Right on, I have an 85 4Runner as well! Your hybrid sounds pretty close to what I would ideally go for, but I would absolutely add tie ins back to the frame. What are you doing for cross bars? I was thinking if I did this I would add a diagonal from behind the driver b pillar to the passenger floor to triangulate somewhere thru the pop top window.

[@csabin312]

Dave's going to join you. I follow him in KZbin and he's an amazing fabricator.

[@WillometMotorFab]

I don't know about amazing, but I've ruined enough stuff to know how to generally avoid it.

[@michaelbahl1809]

Structural, I agree now and a exo cage for me would be more or a rub rail then for a serious roll over. You and Ian made perfect points about roll cage and exo cage

[@20tea]

Really enjoyed the exo cage discussion! I built a full cage into my Samurai, but now plan on removing the rear tub and rebuilding it with tube. Thinking about merging a tube rear tub into the interior cage. Weight is always a concern too with my setup as I currently sit about 2700 lbs which is heavier than I want. Love the progress!

[@johanvandermerwe8507]

Loving this Suzuki build. Thanks for the great content…!!!

[@troydecker9685]

I have followed you for a few years now and to see your skill improve and evolve is impressive to say the least. Dave is a great guy and also a impressive fabricator. I have a 1ton Suburban that I have started to do some fab work on like bumpers and a roof rack. I’m not building a full on crawler but just a fun trail rig/ tow pig for my wife’s TJ. Keep up the great work Nate. I’m loving the collaboration with other channels

[@DirtLifestyle]

Thanks for the continued support, my friend 👊

[@beadblaster9508]

Your fab skills are unreal. You really do need to open a fab shop

[@DirtLifestyle]

Thanks! We are working on opening a shop later this year. Lots of details need to be ironed out but it's a big goal for me in 2023 👍

[@shanemartinson5006]

the cage is looking great so far Nate!

[@DirtLifestyle]

Thank you!

[@jonajames4526]

Absolutely love your channel and as always eagerly await your next episode.Kind regards from Swakopmund, Namibia......which is where you would a ton of fun in the dunes with this build.

[@DirtLifestyle]

Thanks! Namibia might go on the list of places to visit 👍

[@anthonyhodges472]

Fast back was definitely the way to go .

[@Thexkidd]

I always liked the look of a exo cage on a xj for example.

[@Fparrish]

Job well done as always. Also really love that you are bringing in your friends to help with this build, that’s way cool!

[@Voyagersk9]

I’ve work Nate! The build is looking excellent! I can’t wait to see it finished! 👍👍

[@skylinesandro]

Like the attention to detail regarding the rules. I've done a couple of 24hr of lemons cages and their rule book is super easy to understand and is quite safe. I'd double check your harness angle behind the seat. Looks a little steep.

[@dirtyfingersgarage]

That was a great video. Very informative about cages. Great to see Ian involved in the build for sure even if he was just on a vid call. Keep up the great work .R

[@stomis2346]

Just a comment on the cage rules you referenced. Last time I looked at the book a full frame vehicle as per NHRA can only have the main hoop land on the body if there are diagonal bars going directly to the chassis as well. I always thought this was an odd rule until I began running into the circumstance this was exactly written for simply because that limit the bend amount in a main hoop.

[@gonna_try_anyway7047]

Nobody's chiming in on Ivan Stewart's super offroad challenge arcade machine in Ian's back ground. Best arcade game ever!! Dude.

[@tommyd1963ify]

That top center bar will also solve the sagging soft top issue. Had a couple Samurai and we were using CJ7 bikini tops for a little more length/shade than a Samurai specific one.

[@DirtLifestyle]

That was something I wish I had explained lol. After many years of jeep ownership I knew a little extra softop support in the center would be a good idea

[@CTMadModz]

Love this build man, I’m excited for the completed rig

[@DirtLifestyle]

Thanks!

[@mitchellconley9338]

Love where you went with the cage design and how well thought-out and purpose built it is. One point I want to address is DOM tubing IS a welded tube. It starts life exactly like HREW and CREW, then is drawn over [a] mandrel (DOM). True seamless tubing is pretty uncommon for typical fabrication work.

[@TriStateOverland]

You should check out a custom column for that thing - there’s a company here that makes them. Flaming River Industries. I do not work for them, and am not paid by them. They just make some really high end food quality columns. It would look awesome in that thing!! Great work so far man. Really love watching build progress videos like this.

[@gmhrawls67]

If you are building a land cruiser later in the year rather then an exo cage why don’t you do more of an Australian style barwork setup with front and rear scrub bars tied in to the front and rear bumpers and if your keen a set of roof sliders to protect the roof from rubbing against trees? Looks good and protects the vehicle well enough during hard wheeling. Cheers mate love the videos!

[@troylassalle]

Thank you Nate. You given me a new perspective on roll cages. Thing I thought I knew I really didn't . I think this was one of your best videos. Safety first! Keep up the good work 👍

[@DirtLifestyle]

Thank you for watching, man. I'm glad you enjoyed it 👊

[@papa_joe]

Amazing looking cage and design. Love it.

[@taurota1554]

Awesome content as always

[@nrs91]

I think vehicles like the land rover defender are probably the only exo style cage that can get approval and work. They get to the chassis via the "shoulder" of the body so overall width isn't increased and on a 90 pickup you can have the 6 points of contact and triangulation required via the windscreen hoop, behind cab hoop and rear stays.

[@garyfujinami9911]

I had to laugh with you lamenting over function vs beauty especially, after seeing the really cool cage you've created. You definitely have a very creative side. On many of your videos you speak of designing as you go. I am the same way. I hardly ever draw something out. Granted, I've made some turds but that's half the fun. Further, I'm a "functional is beautiful " kind of guy anyway so many times, my stuff looks so plain Jane. You've definitely inspired me to raise my game.

[@heartsky]

Ya I agree, ixnay on the exo.

[@cpthillbilly]

Awesome video!!

[@mazevx2451]

Seeing your cage and having our European cages in mind, yours looks overly complicated, the tubes in the section under the B pillar doesn't seem to make much sense and the "cross" to the C pillar points seems to overly complicated as well but I keep on watching and I'm curious to see it finished! Great build anyway and no judgment!

[@ryanmares692]

This was a killer episode!

[@xTinBenderX]

SCCA and NASA Racing rule books are good too.

[@zanemeyers164]

thats a damn nice lookin cage

[@DirtLifestyle]

Thanks!

[@caseywojciechowski2830]

Great job

[@danpomeroy9952]

All right! Guest appearance from Car-Guy Fieri!

[@DirtLifestyle]

Lol

[@danpomeroy9952]

Great episode! I never miss it. Thanks for the awesome content.

[@RobertLowery]

Thank you for discussing the exo-cage issues. I am working on building a 75 Ramcharger into a safe overlanding and, I would guess, a moderately capable trail rig. I have been considering an exo-cage because it would allow me to also use it as a support for carrying canoes, roof top storage, and maybe a roof tent. My biggest dilemma has been trying to figure out how to reliably support the weight of the vehicle in a roll over scenario. I am now convinced that an internal cage is my only real option. I do not like the idea of losing so much interior space, but I would rather walk away from an accident.

[@insaynbcr]

Nate, you are tooling right down my alley with the tube fabrication. Love it! I couldn't agree more on you and Ian's view on exo-cages. Never built one, never will. To me exo-cages should primarily only be used for body rub rails, a place to put a strap for recovery, or to mount stuff to. Never for occupant safety. Question for you..... Do you find that your bends are slightly off from where you mark your white lines on the tube compared to where they actually land on the tube post bend? I see you reference way out on the end of the die. Do you have an offset built into your calculationed dimensions while using this reference point?

[@charlesswaim1598]

Please be informed as you get the aluminum body blasted. Blasting aluminum with media that has previously blasted steel can lead to corrosion issues in the aluminum. The microscopic pieces of steel will embed themselves in the aluminum. This can cause severe galvanic corrosion. Keep up the AWESOME work!!

[@tacotots_132]

Ohhh so pretty!

[@toddgibbs1321]

You mentioned the seatbelt bar. I think it is worth saying that it needs to be above your shoulders so it doesn’t compress your spine. That leads me to the concern with having the 45 tied into the seatbelt bar. If that gets deformed it could injure your back. You do have a double bar that may prevent that but it is tough to know without an FEA. By gut feel it seems okay, but I also know you really care about the safety.

[@DirtLifestyle]

This is interesting because I have seen a bunch of different opinions on this. The manufacturer instructions call out for the belt to be installed level with the seat holes or lower. BUT the belt can't be any lower than a 20-degree angle. I hope that makes sense?! I installed the last 3 sets of belts in this orientation per the manufacturer instructions. It might be hard to tell in the video but the belt will end up just below level. In any case, I remember hearing what you are saying from someone else at some point. More research might be neccessary... Thanks man 👊

[@toddgibbs1321]

@@DirtLifestyle be safe and keep putting out this amazing content! You are the top of my list and I am working towards doing my own build in the next few years. I am trying to learn everything you are talking about.

[@2thehat]

Had been thinking of doing an exo cages for my 85 Yota cause it's so tight inside but now I'm thinking again. I can see ways to get triangulation on the pickups for the back of the cage without punching into the cab, but you lose a lot of the bed use. Now I need to come up with a new design.

[@wesc4054]

Checkout 4x innovations prefabs

[@2thehat]

@@wesc4054 I've seen it, and it could work, I'm just a tall person so with that cage a helmet wouldn't fit.

[@sweeneyoffroad]

Watching you use Bing made me uncomfortable lol. Everything else was great though! My weekly dose of inspiration to get out in the garage. Thanks Nate!

[@tonycolicchio5505]

Nate, Around the 2:26 mark you show a pic of a BMW cage I built. This cage is extremely well engineered and fabricated. Those gussets are fabricated on top of 1.75"x.095 DOM, the tubing legal for the weight of the car in SCCA cage specs. You took a single pic(actually stolen from my social media without credit) not showing the rest of the cage in its complete state. These gussets were used by BMW for many model iterations as they raced cars in the 2000's, including this chassis, an E46. Time for you to also learn!

[@jordantrujillo293]

What are your thoughts on the XOFAB cage for Jeep Cherokees? Only reason I was leaning towards that was because of how they look like they’re actually structurally safe on the interior. And my purpose for it wouldn’t be to protect the body, but to keep my head away from the roll bars as well as passengers.

[@brennenrowell231]

I am considering that or a similar hybrid cage for my XJ as well. There just isn't much room inside a Cherokee to begin with, so a hybrid cage seems like the only good option.