The old land cruiser FJ40 roll cage mounts were rusted through at the wheel wells and the front A pillars had wrinkled bends so I decided to start from scratch.  We started by designing the new roll cage with BendTech.  It was very helpful for visualizing how different designs of the roll cage would look.  Once we had that out of the way we were able to accurately measure how much DOM tube would be needed.  Most of the roll cage is made from 1.75" DOM and bent with a Pro-Tools 105 manual bender that we converted to hydraulic.

Sometime ago (while I was still driving the 40)  I took out the old roll cage.
  The A pillars had wrinkled bends, the mounts to the wheel wells were rusted out and the welds were terrible.

I wanted the new main hoop to mount to the upgraded main body mounts that attach directly to the frame, rather than to the top of the wheel wells.  To keep the top of the hoop over the driver's and passenger's heads we raked it back a few degrees.

A perimeter hoop around the rail for some side protection. 

The main hoop sits on 1/4" angle iron bolted to the boxed body mount that was added with the diamond plate floors.

I started with four rear tubes that tie the main hoop to the perimeter rail.

Not a very good picture, but it shows the front hoops.  The drivers and passengers pillars sweep back to the main hoop, with a front bar connecting the tops of the two A pillars.  


Gotta check those clearances.  It all fits under the soft top rails

 The rear frame tie-in for the cage will double as the rear body mount.
  Since taking this picture, I decided to use a bushing rather than solid mount.

Rear seat brackets are built into the cage and the front tube can raise and lower slightly to adjust the pitch of the seats.

Seats installed (Even if only temporarily...Passenger's is all the way forward, and the Driver's is all the way back)

A view of the mostly completed cage from the top.