Fabrication of a jeep roll cage and custom seat mounts !

On this episode I dig in deep on metal fabrication and show how I added to my factory jeep roll bar in order to make it more suitable for hardcore offroad use. I also show how I built a seat mounting system and added in reclinable suspension seats. Hope you enjoy.
This is intended for fabrication tips and tricks only. I am not guaranteeing this is a roll cage that will save you or your rig in an accident or rollover.
Intro music Sync ID MB01YOWH8CMJXKK
Tubing bender www.roguefab.com/
Seats and belts. www.prpseats.com/
Welding equipment. www.millerwelds.com/
Belt sander. www.ameribrade.com/
Keywords. Mig weld welding fabrication tube bending tube bender pipe bender miller welder
DIY fab off road rockcrawler rock crawler ultimate adventure

[@Hanky_Bannist8r]

This is the side of your skills alot of us wanted to see. We're now learning why you build a certain way on top of getting to watch you build cool trucks.

[@thedirtheadshed]

I like showing it. So much of the tech stuff got cut on DED

[@Turbochargedtwelve]

@@thedirtheadshed I was always sad they didn’t show more of it

[@jerome4995]

@@Turbochargedtwelve I get the time constraints. I would have liked a DED after hours show. With all the tech to geek out on.

[@deadlastfabshop6920]

I think the simple things are more fun to watch and more realistic for the at-home shop than these high-dollar let's just put a hellcat motor in it crap that's out there now. I wish we could put hellcat motors and everything but we're not sponsored by Dodge

[@scottbutts6703]

One good thing for us viewers is that we now get to see a lot more detail. I've always wanted to hear Dave talk more about roll cages, and here it is!

[@thedirtheadshed]

I feel like I rushed that one a little. We’ll get more into that stuff later

[@danielcarroll5667]

"I just got done doing a whole bunch of engine work on this thing and it still sounds terrible !" thank you Dave ! You're always so honest and it makes me feel good to know it's not only me , roll bar is sweet , keep up the great work......

[@thedirtheadshed]

Thanks. The struggle is real

[@ljsrcandanimals9566]

I saw you at Easter jeep safari 2022 when you guys were with motive gear and ten factory my dads the one who sent you the A&D shirt and hat I’m glad you and Fred are still making videos even after dirt every day ended thanks for keeping us entertained you guys are awesome! 😊

[@thedirtheadshed]

Thanks for continuing to support!

[@markvanvoorst300]

Great early morning therapy for me. Now it is time to go wheel SMORR with some good friends.

[@thedirtheadshed]

Nice! Have fun

[@davidking3311]

Dave and Fred are both quickly up to 50k subscribers like it was nothing, keep up the good work guys

[@thedirtheadshed]

Thanks! We had a little bit of a kickstart. I’m totally stoked

[@Henbervr]

Thank you for showing this side of the fab parts. This is what a lot of us gear heads want to see. For most of us the build is more fun than the finished product

[@thedirtheadshed]

Yeah. This type of stuff is fun. Not too overwhelming, short downtime

[@mh-qq2hj]

You make bending and notching tubing look so easy! I like these technical videos the best

[@ericlattimer]

That intro was beautiful.

[@thedirtheadshed]

Thanks

[@stonethedoctor]

The pacing and amount of info you share is great. Thanks Dave

[@thedirtheadshed]

Thanks! That was a fun project

[@AS-ng5pi]

I like the metal paneling and colors you chose for your walls. Looks good.

[@thedirtheadshed]

Thanks! It was all leftover materials. I need to finish the rest of the shop

[@stevescoville8465]

I’m recently retired after 41 years in the trades and I’m teaching myself (with the help of KZbin) to weld. Watching you weld and seeing the end result is pretty inspirational to me to keep on trying to improve. Been watching you and Fred for years. Enjoying all of it. Keep rolling out the content sir, thanks.

[@thedirtheadshed]

Will do. Good luck!

[@Jagermonsta]

mr chapelle needs a lapel... microphone. this was a great vid, thank you. I'm learning to weld and I love vids like this

[@thedirtheadshed]

I thought I did Good on the audio this time. I left that one clip quiet on purpose. Otherwise the chop saw would have blown out your speakers

[@MacsSpecialitiesMotorsports]

7:10 What else does a guy need? 'A Coffee, A Jeep and A Welder"

[@thedirtheadshed]

Right. Good days

[@rediron44]

Cool video. As a Union Ironworker, who has been a Certified Welder 30 years, and fabricated for years too. Its great to see different ways and techniques guys use to build things. Lovin the content. Great work.

[@thedirtheadshed]

Thank you. We’re all learning. That’s what keeps it fun

[@art8399]

Dave this old man finds your skills amazing.Your a multi talented guy. I will keep enjoy watching you do your thing. thanks for the enjoyment.

[@thedirtheadshed]

Thanks! I appreciate it

[@KGRoberts]

"...engine still sounds terrible. So work on the roll bar..." I just LOVE these dry one-liners 😄

[@thedirtheadshed]

Stupid engines

[@grngoblin97]

Been DED fan since day one and I’m really loving your KZbin content. Keep it coming please.

[@thedirtheadshed]

Will do. Thanks for following along

[@frediefarmer]

👍🏽🇺🇸👍🏽 new sub because of Nate@Dirtlifestyle. Awesome job on showing how and why. Thanks

[@thedirtheadshed]

Sweet! I appreciate it

[@kustomd60]

I like all this fabrication your showing. That skip cutting with the plasma was the best idea ever. I saw you do that on an old episode of ded and it helped me build some cool bag mounts for a car I'm building. It makes bending plate so much easier. Then weld up the slots afterwards. Great content.

[@thedirtheadshed]

Thanks! Glad you are catching the tricks

[@joeroad6618]

All the times I've watched you weld stuff up I just noticed that you are left-handed, excellent work!

[@thedirtheadshed]

Yep. I’m always the weird guy at the dinner table

[@555Slovelle]

Glad you're doing these types of videos. Excellent MIG welding too.

[@thedirtheadshed]

Thank you. Sometimes I get sloppy. Trying to do my best lately

[@MacsSpecialitiesMotorsports]

For sure!!

[@Beat98TJ]

I’d like to see some more detail on chopsaw notching. I have usually used a hole saw notcher, and although it’s been explained to me I can’t wrap my head around chop saw notching angles.

[@thedirtheadshed]

I’ll do shorter videos on a lot of the techniques

[@Beat98TJ]

@@thedirtheadshed cool. I have done a little bit of to work on my own and helped Drew do a bunch of cages on my vehicles. It’s the little tricks that make all the difference when you’re doing that kind of stuff. IMO

[@jesseshelby4383]

Man I sure like your content better now that you went solo. Keep up the good work 🤘

[@thedirtheadshed]

Thank you. It’s pretty fun showing what I’ve got going on

[@jimanderson4495]

Geeeez….what beautiful welds. And… you have amazing fab skills. Joined Fred’s channel this am. You may not have an MT budget, but your products is pretty slick. Thanks Dave.

[@thedirtheadshed]

I appreciate the support!

[@chukhentcy5642]

Dave, You're a Wizard.👍

[@thedirtheadshed]

Not yet. Many years till wizard status

[@jp2246]

24:26 that is impressive

[@thedirtheadshed]

Thanks!

[@kevinzimmerman2304]

Awesome fabbing skills!

[@thedirtheadshed]

Thanks! I would like to get better

[@scottr9900]

You did a materials explanation on one of the Extras that I found pretty interesting. DOM vs HREW vs Cold Rolled, etc. Chrome moly, vs. mild steel. Those grab handles reminded me of that KSR 25.3 cage build.

[@thedirtheadshed]

That extra was a long time ago!! Thanks for the support

[@scottr9900]

Been watching for quite some time. It’s funny how time flies. There was an Extra you did on a Suzu, I think. You mentioned you didn’t need much room for the kids. And then you mentioned recently how your kids are taller than you. Been there.

[@JBarnes917]

Nice to see all the great looking fab work with basic tools most of us could have in our garage

[@thedirtheadshed]

Thanks. I feel like some of it is too fancy, but it’s nice to have sometimes

[@JBarnes917]

@@thedirtheadshed the bender is a little fancy but nothing else I have seen is that bad

[@gladsfur1656]

Really enjoy your channel.

[@thedirtheadshed]

Thank you. I’m enjoying making the videos

[@deadlyfxdb]

Another great video! Thank you!

[@thedirtheadshed]

Thanks for watching

[@pbfab7764]

Bad ass fab, love it !

[@thedirtheadshed]

Thanks dude

[@davidsawyer1599]

I have very little knowledge of roll cages. The fabrication and installation I know even less. That said. Welding the tubing to the body vs the frame.....it's not adding up. What am I missing? Even with the sandwich plates. To my way of thinking it's going to tear out. Just not as fast. I am not trolling you. I am not saying you are doing it wrong. The Welding is no doubt top of the line. The triangulation is great. The placement of the grab bars is insightful. The principle in arching the head bar is spot on. The attachment to the body vs the frame. What am I missing?

[@thedirtheadshed]

There are always compromises in any build, this is a basic entry level type of cage. A lot of people would like a little more protection, a little more peace of mind. And don’t necessarily want a rigid mounted cage and the inherent vibration associated with it. The next steps on this one would be to do urethane bushing plates on the backside of the base plates. Then steel stantions to the frame. That may happen or it may not.

[@davidsawyer1599]

@@thedirtheadshed Cool. Thank you so much!

[@stephenlewis8143]

Thanks Dave, the nuance, detail & tips re the tubing and roll cage is informative - and the emphasis on safety, a benefit to us viewing; & for future passengers. When you are finished, possibly your family or friends can land in the seats & we can see the smiles on their faces - from all of your work.

[@thedirtheadshed]

I’ll do more on this rig for sure

[@Thexkidd]

Hope you had a sun shade 🌞

[@thedirtheadshed]

I put a soft top on it

[@BadgerRacingInc]

Awesome content. Leave the clamp block(s) on the tube and pull pin when test fitting bends. That way you can re-insert the tube into the bender quickly and the tube will be clocked correctly 👌

[@thedirtheadshed]

Great advice!

[@4x4_mark]

Pretty rad

[@thedirtheadshed]

You’re pretty rad

[@SuperMorgan40]

Thanks for pointing me toward PRP. Been looking for suspension seats for my Jeep and Bronco!

[@thedirtheadshed]

Nice! I dig them. They got really good after a week in them

[@nickhermo2936]

Awesome work brother. So glad that you’re keeping the content going. Love it.

[@thedirtheadshed]

Thanks for watching. It helps keep me motivated

[@christopherwedemeyer2993]

Really enjoy.your content. Don't ever stop giving away the knowledge chunks!

[@thedirtheadshed]

Can’t take it with me!

[@barrymccociner6802]

Really enjoy watching you share your fab ideas and skills. More than one way to do things so it's fun to watch with an open mind. Keep it coming !

[@thedirtheadshed]

I appreciate that. Thanks for watching

[@victorwest8041]

good welding !

[@thedirtheadshed]

Thank you

[@BennyHubba]

Looks great!

[@thedirtheadshed]

Thanks

[@elshamrocko]

So rad!

[@thedirtheadshed]

Thanks. It’s like medium rad

[@old_con]

Coming together good. Really enjoying this jeep build. 👍🏽😎

[@thedirtheadshed]

Thanks, me too

[@jesscneal]

Amazing work Dave. Fitting roll cage bars is a pain in the ass and you make it look easy 👍

[@thedirtheadshed]

Thank you. It’s good when it’s good. Can still fight you though

[@steveornot]

Awesome stuff dude

[@thedirtheadshed]

Thank you

[@aaronmcconnell7358]

Thanks for knowledge Dave, the tip on putting the crown in your top bar was something I hadn't that about . but after you said It can remember my factory cj7 bar having just a little bump up in the bar. So grateful to have "the Dirthead Shed"

[@thedirtheadshed]

Thanks! I dig when people take something away from it

[@aaronmcconnell7358]

@@thedirtheadshed its like what we wanted shop teachers to be like back in highschool

[@joeyvattiato9768]

Dave i love ya channel brother,i hope you do so well that MT really regrets cancelling your and Freds show

[@thedirtheadshed]

I appreciate the support

[@LowerWeldingShop]

Rad episode!!!!!

[@thedirtheadshed]

Thank you

[@Hickeyjones]

Love the offset grab handle idea. 😎

[@thedirtheadshed]

One of my favorite tricks

[@Kyle-ev4fk]

You should do this for a living you're pretty good at it.

[@thedirtheadshed]

Thanks! I’m still practicing

[@shawnsnodgrass6005]

On your next video tell us how you like your midnight metal works rock box

[@thedirtheadshed]

I will

[@DeathRockRadioTampaFlorida]

coming along awesome !!!

[@thedirtheadshed]

Thank you

[@JMKady76]

Tips on top of tricks on top of good ideas! Lots of good ones in this vid for newbie cage builders like myself.

[@thedirtheadshed]

Glad you got some good info from it

[@davidaxman]

I love seeing your videos, keep it up!

[@thedirtheadshed]

I’ll keep filming !

[@coonlakebackwoods]

Thanks for another great video Dave.

[@thedirtheadshed]

Thanks for watching it!

[@joshuazientara4452]

Looks good!

[@thedirtheadshed]

Thank you

[@jeffreybetts8014]

Love watching this stuff, great video, thanks again

[@thedirtheadshed]

Thanks for the support

[@MiloPerrotti]

Thanks, great content.

[@thedirtheadshed]

Thank you

[@trevortorrens5028]

Great work and great video Dave!

[@thedirtheadshed]

Thanks! It’s making for a good little jeep

[@waynedodd8764]

Looking forward to seeing it finished dave

[@thedirtheadshed]

It’s a fun rig. Will probably always be a beater though

[@saxonstangsetc3201]

Amazing Fab work and design! Use a mic for sound and an outro to the end of the video would be awesome!

[@thedirtheadshed]

Thanks

[@vetguy2562]

Excellent video and thanks for the teaching side of things Dave 🤘😎

[@thedirtheadshed]

No problem. Thank you

[@justinshultz120]

Nice work Dave 🤘🏻

[@thedirtheadshed]

Thank you

[@mojave_ric]

You do amazing fab work Dave

[@thedirtheadshed]

I appreciate that

[@woodshed09]

More work getting done. Good stuff

[@thedirtheadshed]

Thanks wood shed. I just built a wood shed!

[@floydstowe]

Looks strong very nice

[@thedirtheadshed]

Thank you

[@BestUnderPressure]

This is exactly the kind of videos I like. Do you plan to make any shirts or hats in the future?

[@thedirtheadshed]

Thanks. Yeah. Working on shirts now

[@Wrenchingandadventuring]

Man genuinely enjoying this new channel. Actually been looking at YJ’s to kind of copy your project. Keep it up Dave!

[@thedirtheadshed]

They are good rigs. And the price is right

[@xozindustries7451]

Great work, I wouldn’t think to build off the factory cage, but it came out good

[@thedirtheadshed]

Thanks. I use to do setups like this for a bunch of Jeep club guys I did work for. Helps in a rollover, doesn’t cost a fortune, doesn’t impede on your space or vision too much

[@KRock393]

A lot of work and looks great! 💪🏼 Strong like Bull

[@thedirtheadshed]

Thanks! It IS a lot of work

[@KRock393]

@@thedirtheadshed ready for some more Hard Body progress as well, but great seeing more work like this! 👍🏼👍🏼

[@brentheltsley7187]

Funny, the dealership down the street recommended the same thing when I brought my Camry in for a drivetrain issue

[@thedirtheadshed]

They are always trying to sell roll cages at the dealership…

[@PaulKaiser42]

Dude that rig is coming along nicely!!! Looking forward to hearing how she does at UA

[@thedirtheadshed]

Thanks. It worked really well

[@jeremypoindexter4834]

I need that front half “kit” for my yj. Awesome work

[@thedirtheadshed]

Break out the welder!

[@JeffHarbert]

Nice work, Dave. Your skills are amazing and I love this kind of content. (Trailer hitch from scratch next? My limo needs one.)

[@thedirtheadshed]

I’m down for all this kinda stuff

[@iansprojects3081]

U are definitely learning this KZbin stuff fast every video is better then the previous one and I am not saying any were bad videos they are all good I just mean it’s not any easy thing to learn

[@thedirtheadshed]

Thank you. It’s a hustle

[@GarthR]

8000 views in 7 hrs let’s gooo cheers for the upload

[@thedirtheadshed]

That’s rad. Thanks

[@SteezerZimmer]

Yaaa nice shirt!!

[@thedirtheadshed]

Thank you

[@ericmaurerdesigns]

you have a day job? Come on, with a YT channel like this, the hundos should be flowing like the snake river. :) So.... did you go back to pole dancing or are you hocking parts at 4WP? We all have to have day jobs to spend our second job working for free on our own stuff. Kudos DC, glad to see your channel blowing up so fast.

[@thedirtheadshed]

Yeah. I work on trucks during the day so I can work on trucks at night. I thought the KZbin money would go in the bank, but it just buys parts for the next truck related KZbin video…. Am I doing it right?

[@tree18is]

if TFS has some tool sponsers so should you, Cold saw and notcher first up!

[@thedirtheadshed]

I wouldn’t mind a tool sponsor for some stuff. But it’s not all that necessary. I also like showing the more basic techniques

[@tree18is]

I Have a model 32 bender but that window on the Rogue is way better

[@thedirtheadshed]

It definitely helps

[@saturnfivehynrgrc581]

Watching this Dave is motivating me to start brazing (learning how) RC crawler cages and bumpers. Noticed the paper on the window. I assume its to keep the welding sparks from pitting it? And of course while painting. Great job on the channel man. Moms spaghetti is my favorite. Cheers!!!

[@thedirtheadshed]

Thanks, yeah the paper is to keep the sparks and spatter from ruining the glass. Good luck on the brazing. That’s something I’d like to learn too

[@jamesthefordman]

Great content man hope to come check out your shop someday soon and you def gotta wheel out at Kaiser before the homes go in out back

[@thedirtheadshed]

That’s for real. Need to make it happen

[@petecrabtree6734]

🦅🇺🇸💪😁👍 keep on keeping on

[@thedirtheadshed]

Doing it!

[@nathanwoten6236]

Dave you should check out a tubing roller. They have some pretty inexpensive units out there that get the job done just fine

[@thedirtheadshed]

I have a harbor freight one. Never use it

[@monette44]

nice!

[@thedirtheadshed]

Thanks

[@Rivetroad]

Loving the content @dirtheadshed I can’t be the only guy who enjoys building this stuff more than I do wheeling it. I do have a question though and would love to see it explained in some detail. How do you figure out your tube loss when bending? I always struggle to get my lengths exact on the first go. Surely there’s an easy way to do it.

[@thedirtheadshed]

We all struggle with that. I’ll explain more of my techniques in a more in depth video.

[@jtsharp3000]

Thanks for showing the Rogue Fab bender in action. I’m considering this for my personal shop and it’s nice to see someone who I know has experience with a JD2 also using the Rogue. My main concern is the amount of clear area needed around the bender. Seems like the Rogue has some advantages there as long as your ceiling isn’t too low.

[@thedirtheadshed]

I’m still figuring it out. I’m not sure how to do certain s tyoe bends without it hitting the ram

[@jeremyhowell2332]

@@thedirtheadshed I’m really struggling on deciding between the Rogue Fab 605 and the elec/hyd JMR. Seeing that you picked up the Rogue Fab weighs heavily on my decision. I feel like you’d choose what works best regardless of price within reason. I’m sure any company would hook you up for the marketing. Can you help an indecisive guy out?! RF or JMR?!

[@morphsticles]

Dope

[@thedirtheadshed]

Thanks

[@rustybottoms8859]

Thanks for sharing Dave. You do an awesome job with this fab work, I truly admire it. What did your buddy figure out on the engine? WAS it compression? I am sure you have it figured out now but I was thinking maybe collapsed lifter? Keep on keeping on and most of all have fun!

[@thedirtheadshed]

Compression is fine. I think the pistons are rocking it slapping in the cylinders

[@fbombfab1606]

Shouldn't the floor plates be one bigger than the other to prevent tearing of the body?

[@thedirtheadshed]

That makes sense. Hadn’t heard that before

[@rickrutkowski5056]

great idea on the seat mount, the factory ones are just too high for aftermarket seats!

[@thedirtheadshed]

So tall!

[@LifesGreatNate]

What thickness of sheet metal do you typically use when fabricating seat brackets? As always, enjoy seeing your content and hearing your thought process for the work you do.

[@thedirtheadshed]

I use 3/16 plate for practically everything

[@scottr9900]

Good looking fab work as usual. I meant to ask if you were planning on doing some sort of merch? That crown acts a little like triangulation, right? Load on top has to force the other bars to deflect. Kinda like a tube spring.

[@thedirtheadshed]

Correct. Yeah I’m working on some shirt logos now

[@scottr9900]

I’d keep it simple. The show logo is good. Maybe a line drawing of a mountain silhouette over top of it.

[@hanselgretel8563]

Yes. Roll cages in the UA actually do get "used". 😄

[@thedirtheadshed]

Sometimes!

[@EngiTrek]

Idk, I think DED getting cancelled was a blessing in disguise.

[@thedirtheadshed]

It was definitely a good time in my life

[@joem8384]

Awesome video Dave!! Love the YJ! Did you have to relocate the parking brake release for the new cage?

[@thedirtheadshed]

It still works, but it’s not convenient

[@rescuedandrestoredgarage]

Great video brother it's awesome watching how you're mind works when you are having fun with Fabrication. The jeep is coming together in a big way and how is the engine doing did you get anuff time for the compression test 🤔

[@thedirtheadshed]

Compression test was good. Really not sure why it sounds so bad

[@rescuedandrestoredgarage]

@@thedirtheadshed its not a ford food for thought lol