RZR ROLL CAGE BUILD - Extreme UTV Tech EP3

On this episode of Extreme UTV Tech We head up to Jake Burkey's shop in Augusta, Georgia to do a full custom Cage build on the Busted Knuckle Polaris RZR XP 1000 including custom front and rear bumpers. We show you how to build a RZR Roll Cage for your machine. Parts for your custom cage build can be purchased from us at www.bustedknuck...
If a full cage built is too much for you. No bender? No Problem. Here are a few weld in kits to strengthen your factory cage.
Factory Cage Brace Kit- amzn.to/2fGiOSb
Body Protection Kit- amzn.to/2fGkMlw
Front Bumper- amzn.to/2ghIoQT
Rear Bumper- amzn.to/2fGkZF2
DVDs & APPAREL - www.bustedknuck...
Follow us on Facebook - / bustedknucklefilms
INSTAGRAM / bustedknucklefilms

[@SOCALLEO15]

This is probably the best off road fabrication tutorial there is on KZbin 💯👍🏼👨🏻‍🏭💪🏼🥇

[@BustedKnuckleVideo]

Appreciate that, Jake Burkey knows his stuff check out his new channel for more- kzbin.info/door/bOUUPmH1YoFXHRQuZarA5A

[@GregoryJohnston77]

What absolute beautiful cage guys.

[@BustedKnuckleVideo]

Thanks!

[@TommyBlanton]

On the bucket list! Just finished my light bar build and on to bumpers now. It would be kick ass to see a 4 seater cage build.

[@BustedKnuckleVideo]

4 seater is just like this one with a few more tubes

[@CTDMUDRUNNER]

Light bar before a proper cage. Priorities. lol

[@james4wd236]

It looks easy enough. Being the type of guy that never pays anyone to work on my stuff, this video encourages me to buy the material and make a cage myself. Probably wont be quite this complex, but I think I can do it.

[@BustedKnuckleVideo]

Nothing to it

[@juanpina3368]

Great video keeps it simple thank yiu

[@BustedKnuckleVideo]

You bet

[@belloautomotive1522]

That sheet metal top was the perfect canvas to do some bead rolling! Anyway nice work guy

[@BustedKnuckleVideo]

If only we had a bead roller

[@The_BillingsFamily]

What size gauge was that sheet metal?

[@magna-mogg6598]

Super job, thanks for the tips !!

[@BustedKnuckleVideo]

thanks for watching

[@FusionOffroad]

Great Video, I might try to build one now. I dont know if its a good thing or not

[@BustedKnuckleVideo]

Go for it!

[@ReshardsAutomotiveWorkshop]

One of your best videos! 👍

[@BustedKnuckleVideo]

Thanks!

[@BigD1395]

Sorry Matt, for cheering you on before I seen your struggle. Hey, "sometimes"some ppl cane just see the beginning from the end. Heck yeah bring geometry into it Burke!

[@BustedKnuckleVideo]

I was pretty competitive in that RZR

[@mrsillyname]

well done!!! Jake you da man!

[@BustedKnuckleVideo]

dude knows his stuff

[@lukeblodgett8382]

that stuff is pretty cool

[@BustedKnuckleVideo]

we do what we can

[@ScH3DuL3MxCRoCkR3D]

How did you know where to make the 2nd and 3rd bend? Never explained it.

[@BustedKnuckleVideo]

guesstimate

[@367scotty]

wish it was that easy lol nice job. I want one. Failed with that paint job though. hammerite next time makes a bad sprayer look good

[@BustedKnuckleVideo]

Looked good d held up well

[@mandosgarage]

Can you guys Rey load this ? The audio is messed up

[@BustedKnuckleVideo]

what part is messed up?

[@williamtsol636]

great video bro ! thanks

[@BustedKnuckleVideo]

thanks Jake Killed it

[@sm.offroad]

I can't believe after all of that they didn't powder coat the cage!!

[@BustedKnuckleVideo]

Aint nobody got time for that when you are racing!

[@Ryan-hp6xt]

Just going to scratch the crap out of it anyways. If I powder coated my RZR I'd be painting every week. It doesn't go one ride without going through hell. Rustoleum spray paint is the best, quick, easy, protects shit. Disclaimer: This one's not mine Why pay $$$ for a nice powder coat you're going to fuck up constantly?

[@alfonsomartinez1984]

I see that in some of the welds you pull instead of pushing. Could you tell me more about why and how it affects the weld? Thank you.

[@BustedKnuckleVideo]

good question

[@bustedknuckleoffroadllc5060]

"pushing" a weld creates a lower wider bead profile. "pulling" a weld gets better penetration. I usually push to start a weld using my machine ramp in to get good penetraion at the beginning with a low profile bead then transition to a pulling weld around the back side so the weld gets consistent bead profile and penetration.

[@8BWN]

Was hoping you would have painted it red, still looks sweet though.

[@BustedKnuckleVideo]

We are going for that murdered out look.

[@rogerl8488]

love it thank u!! what size tires an brand an rims u have on it?

[@BustedKnuckleVideo]

29 SX stickies on 15" beadlocks

[@jordangress236]

What pipe bender did you guys use?

[@BustedKnuckleVideo]

it was a homebuilt one

[@jordangress236]

@@BustedKnuckleVideo would you know a good one to buy?

[@colebaldwin3532]

Jake you kick ass!

[@BustedKnuckleVideo]

Guy knows how to build

[@kjbigslim]

Do you use centerline measurements? I couldn't tell exactly where you were measuring, and how you made it accurate.

[@BustedKnuckleVideo]

yes we use centerline

[@kjbigslim]

are you eyeballing the center of the tube, or do you have a method to find center?

[@BustedKnuckleVideo]

We measured with a tape

[@kjbigslim]

got it. I'm just being a perfectionist. Trying to start building cages, correctly, just haven't done one yet. I liked how yours turned out.

[@BustedKnuckleVideo]

Jake is a huge perfectionist. He measured and double checked everything. Even scrapped a piece of tubing for being 1/8" off

[@elpescado8949]

Great video! This video was so helpful, thanks man, I’m looking into this type of stuff but I’m like barely getting into it, do u have any tips or like can u tell me what types of classes I should take in order to learn to make utv chassis/roll cages and such, I plan on making changing the chassis of a rhino once I learn all the necessities (I apologize if I sound very noobish, I don’t know much about custom cages and such 😂)

[@BustedKnuckleVideo]

Any Fabrication Classes would help.

[@elpescado8949]

BustedKnuckleVideo alrighty thanks man

[@brucemcdonald166]

awesome.

[@BustedKnuckleVideo]

nothing to it

[@chrisburnsed6349]

Autocad is waaaaaaay quicker and efficient in designing . It’s easy to make changes and it measures it all out for you.

[@BustedKnuckleVideo]

We got it whooped now

[@nateridesabike]

when you weld to it do you disconnect the battery or run a close ground?

[@BustedKnuckleVideo]

We didn't, but it wouldnt hurt

[@Tombomb1816]

I would leave it connected, a battery can actually act as a buffer and help protect other electic modules on the car.

[@bryceh2876]

thanks for the video i think im going to build me one now. i need to buy a 1.75 die for my bender what is the radius of the die you used thanks.

[@BustedKnuckleVideo]

You can get away with a 180 most likely

[@bustedknuckleoffroadllc5060]

hahaha

[@bustedknuckleoffroadllc5060]

The die radius is 7".

[@douglasalan7786]

No . You dont want to tension something and then tack it together. Get it right without the strapping. Dont get me wrong. You do VERY nice work. Just sayin. I was trained by Overfelt.....back in da day

[@BustedKnuckleVideo]

This is a real world tip for people attempting to build a cage in their own garage. We are not experts we are simply showing people how we did it and how they could solve potential issues during a build.

[@bustedknuckleoffroadllc5060]

we ARE experts. This is the right way to build a cage.

[@bustedknuckleoffroadllc5060]

Douglas. You are incorrect sir. We were not using the straps to "tension" anything. We were using them to hold the pieces together for alignment purposes. I never pull bars together with force to compensate for a bad tube cope. These bars fit together perfectly and were just being held by the straps.

[@BustedKnuckleVideo]

Get on him Jake! lol

[@tylerlaughlin8477]

How exactly are you cutting the sheet metal?

[@BustedKnuckleVideo]

Plasma, but a skill saw would work also.

[@zeppy1311]

what pipe bender are you using

[@BustedKnuckleVideo]

That is a homemade bender.

[@bowtie4315]

www.gottrikes.com/Tube_Bender.htm There is a ton of information on these out there. Just finished mine up and works fantastic.

[@hiltanmclachlan7175]

his voice is soothing lol

[@BustedKnuckleVideo]

Has a face for Radio too LOL

[@patrickjohnson548]

have you done any pro fit Rangers? can't find a video anywhere. you are certainly more than capable! Awesome work

[@BustedKnuckleVideo]

Jake can custom build for anything, hit him up at www.bustedknuckleoffroad.com

[@jacobsmothers9352]

What tube bender is that?

[@BustedKnuckleVideo]

Home made

[@jacobsmothers9352]

It would be awesome to see a video on it. Does is use jd2 dies?

[@BustedKnuckleVideo]

He sold it and we purchased a new one

[@Michaelmagallan4555]

👍👍

[@BustedKnuckleVideo]

👊

[@Michaelmagallan4555]

BustedKnuckleVideo Damn I’m impressed bro nice work 👍👍

[@sxsoutdoorsports9259]

Nice crocs. 😅

[@BustedKnuckleVideo]

that is all he ever wears around the shop

[@ajec2451]

Excellent job fellas!!! It looks fantastic! But for god sake put on a set of leather sleeves... your gonna look like a f'n leper lol

[@BustedKnuckleVideo]

just some welding tan

[@YoBoyReese21]

Orr.....you could just beef the stock cage up and save money and time!!!!

[@BustedKnuckleVideo]

That would be a waste of time and money. The stock cages are not safe even after bracing, and please tell me you are not one of those people that want to "chop" their stock cage SMH

[@YoBoyReese21]

BustedKnuckleVideo o alright

[@bobbyt3358]

@@BustedKnuckleVideo I was thinking of putting some braces in mine but not chopping the stock cage. Would that do any good? Thanks in advance for an honest answer. Mine unit is a 2021 High Lifter. I know this was a older video. But have newer ride cages improved?

[@idkwutimdoin6639]

Anybody else experience some audio issues in this video?

[@BustedKnuckleVideo]

On what part?

[@idkwutimdoin6639]

@@BustedKnuckleVideo the whole thing. The video and audio were timed differently

[@idkwutimdoin6639]

@@BustedKnuckleVideo still a great video though. I watched it all the way through even with the audio lol

[@BC5391]

Outstanding, except using that POS Lincoln

[@BustedKnuckleVideo]

Don't give me none of that brand loyalty BS

[@Cumminslife]

wow, you make it look easy!

[@BustedKnuckleVideo]

ha, thats 2.5 days of work and filming

[@divijam9946]

You did a great job, thanks for the info.

[@BustedKnuckleVideo]

Jake knows his stuff for sure

[@Ryan-hp6xt]

What pipe bender are you using? Sounds like it's running on compressed air, can't find anything like it.

[@BustedKnuckleVideo]

Home built one

[@atvdudes]

nice lookin cage

[@BustedKnuckleVideo]

thanks

[@mrmidnight32]

Great video and sick looking cage man!

[@BustedKnuckleVideo]

Thanks! we sell them now at bustedknuckleoffroad.com

[@masonmainpage4105]

Great fab but why use spray paint after all that work? At least use 2k paint with a HVLP or power coat

[@BustedKnuckleVideo]

racing scratches it up, it's nice to be able to touch it up with ease

[@valleywrenchin]

Hey bro, what kind of bender are you using?

[@BustedKnuckleVideo]

Homemade

[@valleywrenchin]

@@BustedKnuckleVideo nice!! I like how smooth it seems!!

[@onestrangeone2499]

all that work just to rattle can it ! quality like that deserves powder coating

[@BustedKnuckleVideo]

Nobody has time for that.

[@onestrangeone2499]

+BustedKnuckleVideo I guess only the professionals do

[@BustedKnuckleVideo]

Right. I am not a pro cage builder. Rattle can for the win!

[@tomthompson7400]

cage is great , but a bit of detailing on the lid would have been nice .. even a few crease lines or swage lines or something.

[@BustedKnuckleVideo]

It worked great

[@tomthompson7400]

@@BustedKnuckleVideo it was just so it didnt look like a farmer stuck a bit of tin on the roof , as the rest of it was so nice.

[@BustedKnuckleVideo]

I don't really agree with that but ok, I guess we could have bead rolled it some

[@ttk_rufus_gaming]

Do you guys replicate if I wanted to buy? I have a 2016 high lifter 1k and would love a replica of this cage on my rig.

[@BustedKnuckleVideo]

We could but it would cost $3k

[@rzrlife3880]

Very helpful.. Thank you

[@BustedKnuckleVideo]

Thanks.

[@djnemesis82pluss1877]

Nicely done but my harness top straps just wrap around the roll cage itself instead of bolting to tabs seems like a better idea to me but I don't have the cutouts in the seat either lol

[@BustedKnuckleVideo]

yeah they ten to move around when you do the wrap around style

[@rzrscott7355]

If you did the cage build in one day how many hours would you have in the welding ?

[@BustedKnuckleVideo]

This took about 2 days with us filming. You would probably spend a couple hours welding total.

[@rzrdaze]

Audio is way out of synch with video. I cant watch it like that.

[@BustedKnuckleVideo]

really? which part?

[@rzrdaze]

@@BustedKnuckleVideo from the beginning. I watched up to about 3 min mark. I tried reloading page and still out of sync by 4 to 5 seconds is my best guess. You have great content so I really wanted to watch this. Using google chrome browser on Windows 10 machine. Tried on Windows Edge and it works fine. Whats with chrome these days? Anyway . . .

[@BustedKnuckleVideo]

strange

[@dylandriskel6835]

How are you calculating total length of cross members with notch? Are you using the 1/3 of tube diameter for notch depth and how can you figure out notch degree on a bent tube. I’m looking to fab one up but afraid to mess up with cost of material. Thank you

[@bryannelson-airtimegrafix6954]

hey got a ? for ya if your still around!! ive got a 2015 mav xds turbo. my buddy has a jd bender but just a 1.5 die! is 1.5 dom good for a cage? cause every cage bung I see is 1.75! I can machine the bung down to 1.5 no prob. my pre runner was 1.5 and waaay heavyer than a can am!!

[@BustedKnuckleVideo]

1.5 is no problem

[@billcharlene1450]

Clean!!! I built a set of bumpers for an rzr a few years ago, those angled headlights were a pain in the dick to get bars even, measured six ways from sunday to get em lookin purdy. Getting the pipe to bend where you want it too looks like a task. One day i will no longer be ahhh grasshoppa!

[@BustedKnuckleVideo]

Yeah it takes a lot of measuring but the results are worth it

[@gracenhelton9026]

Y'all built the windshield cage wrong . The v goes the other way. I say that because when you receive an impact from the top the way you have it,it will bend the bar that goes over the dash board . When you have it the correct way like y'all did in the back, the weight gets evenly distributed

[@BustedKnuckleVideo]

it still transfers the load, it is all about triangles, they work both ways

[@tommygomez2692]

Guys I loved the video and the quality of the cage. How much for a RZR 4 1k Cage? Also can I get it with front and rear windshield? thx

[@BustedKnuckleVideo]

We don't build them to sell.

[@tazzthedoodle7861]

Man you guys were young lol.

[@BustedKnuckleVideo]

back in the day, but hey we are still young

[@tazzthedoodle7861]

@@BustedKnuckleVideo yes we are brother!!

[@dorianjuarez5383]

Whats the reason behind the tig welding those spots vs mig welding? Just trying to learn

[@BustedKnuckleVideo]

heat

[@nathanielarnold3294]

How much does a cage like this cost to build because I am looking to build one for my Rzr

[@BustedKnuckleVideo]

If you have all of the tools, only around $500-800 depending on the tubing you use

[@rickymartin5881]

Around how much should a custom cage cost??

[@BustedKnuckleVideo]

They range from $800 to $2000

[@onestrangeone2499]

I'm just flicking ya shit good work

[@BustedKnuckleVideo]

we do what we can

[@newlion7013]

Did you guys invent roll cages??

[@BustedKnuckleVideo]

invent them? lol no

[@bobberbuilder6122]

Gotta love harbor freight tubing notchers

[@BustedKnuckleVideo]

work like a charm

[@kantonsmith9907]

Where do I get a rotation gauge like that?

[@BustedKnuckleVideo]

Let me ask Jake. or hit him up on Facebook

[@nicklucey477]

Great video. Lots of info.

[@BustedKnuckleVideo]

Glad it was helpful!

[@horsepowerranch7557]

What roof fasteners are those

[@BustedKnuckleVideo]

some crappy ones. I swapped them to some Stainless hardware once I got home with it.

[@pookie9849]

I want to put a exo roll cage on my truck. So I can use this method right?

[@BustedKnuckleVideo]

yes you can use the same methods,

[@pookie9849]

Thanks:)

[@Tombomb1816]

Explained very well.

[@BustedKnuckleVideo]

Jake knows his stuff

[@tonybriley2100]

Once again, Great video guys!

[@BustedKnuckleVideo]

we appreciate the feedback! we are getting better at these

[@thomascantrell5165]

awesome video

[@BustedKnuckleVideo]

Thanks!

[@jaredflaming5320]

What type of welder did you guys us

[@BustedKnuckleVideo]

a Small Lincoln

[@jsburkey]

Lincoln 210mp

[@hoagiesherlin7732]

looks killer !!!

[@BustedKnuckleVideo]

Thanks!

[@hidayatnoor5291]

Mantap

[@BustedKnuckleVideo]

Gamer talk

[@ClimaxSlushies]

First off amazing video, and do you think it would be more beneficial for me to just buy a cage? Or build one myself? ps. I'm a craftsman and carpenter plus I can weld?

[@BustedKnuckleVideo]

depends, If you have the time and the tools I say build your own.

[@ClimaxSlushies]

+BustedKnuckleVideo yes I do, and thank you for replying. I say I'm just gonna build my own!

[@BustedKnuckleVideo]

good call

[@ClimaxSlushies]

+BustedKnuckleVideo yes sir and thanks for your input and glad imma build a cage, the cage I want with a speaker system was 2750$ before labor

[@BustedKnuckleVideo]

yikes

[@cjcamp4871]

That cage looks awesome

[@BustedKnuckleVideo]

Im super happy with it

[@irvingdanielromero]

hey what kind of bender is that

[@BustedKnuckleVideo]

home made

[@irvingdanielromero]

you should make a video on it

[@BustedKnuckleVideo]

Ill ask Jake

[@bowtie4315]

www.gottrikes.com/Tube_Bender.htm

[@Jizden_Mipanz]

The perfect rzr cage!

[@BustedKnuckleVideo]

Still running a similar cage to this day

[@patsyalcala824]

Where are you guys located.? I need this

[@rhuaustin9004]

great video ..you make it look easy

[@BustedKnuckleVideo]

Its not too difficult with the right tools

[@rhuaustin9004]

BustedKnuckleVideo whats the easyest cheapest bender you recomend .im startting on my cage build after i get bender.im planning on 1 7/5 o 95 for cage is that ok thsnk you

[@BustedKnuckleVideo]

There are quite a few to choose from. The one we used is home made. Do some research on budget options

[@bowtie4315]

www.gottrikes.com/Tube_Bender.htm Fantastic bender if you are good at fabrication.

[@dapipelinerfrommo.5506]

Oh yes, the rattle can! here's a great tip.... find a professional paint supplier and have epoxy primer and epoxy paint put in your rattle can. Here theyre $20 a can....That stuff will survive a direct nuclear strike and 10x the corrosion resistance of PC when scratched. Hell youll cuss a guy next time he insists on PC. Great cage and nice touch with the slash cut bumpers to finish it out.

[@BustedKnuckleVideo]

Thanks. I like the Flat Black engine enamel.

[@idriwzrd]

So, where does the load go from the front dash bar? What keeps the front 'kickers' from folding right into the bodywork? The fab work is good, but the design could use be better.

[@BustedKnuckleVideo]

the front kickers are for looks and a little bit of protection. It's way stronger than the factory cage and worked great while I had this machine

[@idriwzrd]

@@BustedKnuckleVideo Thanks for the reply.

[@bburg1776]

Looks good but its too bad people waste their money on Polaris. When it burns make sure to get an X3

[@BustedKnuckleVideo]

I'll stick to my RZRs