most (albeit few) jeeps I've seen have a pretty elaborate (read: jungle-gym) roll cage from the factory.
when almost any modification gets done to the interior, how are all the bars handled? built around/ cut through?
this is just thought fodder now, but will become seriously relevant in 12 months.
thanks
Back when I was doing semi extreme trails I would expand the factory roll bar (build around) to include a top loop with a diagonal bar, a windshield loop (with a bar across just above the dash. and a diagonal bar from the passenger side floor
to the driver's side roll bar corner. the object being to triangulate the bars where ever possible for strength.
Just an opinion but I would prefer not depend on the factory bars in a serious/multiple roll (they are likely OK for flops); the OEM set ups are far from a triangulated roll cage... that said I did see an old CJ with the stock bars after a multi roll down Potato Salad Hill (Moab Ut.) with surprisingly little vehicle damage.
On the TJ I would do similar to with the addition of a cross bar and a diagonal above the rear seating area and probably diagonal bars on each side.
When modifying/ making roll protection; I fish mouth the added bars and grind the paint off the existing bars, bevel the fish mouthed bar and to about half thickness then weld them in place...
I don't believe that I have ever had to cut a roll bar but I have used thick (3/8") plate to take the bar attachment points down to the frame (especially in back).
There are some clamp on cross bars available, I believe; and multi piece weld tighter roll cage kits. (for those without access to a bender).
I can't see clamp in/on bars being as strong as a proper weld, 'though it would likely be better than nothing.
