Repairing Cage. Need input from you welders.... - Arctic Cat Prowler Forums: Prowler UTV Forum
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post #1 of 11 (permalink) Old 04-07-2014, 09:25 AM Thread Starter
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Repairing Cage. Need input from you welders....

I'm going to repair my rear cage (well at least one of my novice welder buddies will be). Previous owner made the mistake and cut the feet off that mount in the bed. So I'm looking to have extensions welded on. Right now, the current feet are not cut square at the bottom. So I had some questions for you welders out there.

1. Should I take the cage off, try and cut the feet square, and just butt up new pieces to existing and have welded? Will that work, or do I need like a small inner sleeve to slide into both pieces at the joint? What would your typical welder do?

2. A friend brought up the idea of taking tubing and necking it up to slide over the existing 1 3/4" OD tube feet and then welding the two together (no worry if existing feet are square at bottom). What are your thoughts on this? Would matching 1 3/4" OD tubing work to stretch it out to fit over existing? If I go this route, I'll have to go to a machine shop to have them stretch the tubing as I don't have the equipment for that.

I have posted a picture of what I'm trying to repair.
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Name: Shane

-2011 Polaris RZR-4 800 (SOLD)
-1999 Polaris Sportsman 500 ATV
-2006 AC Prowler 650XT (SOLD)-- updated bevel gears, updated oil pump driven gear, 4 wheel disc brakes, line lock E-brake, Papa Slap clutch, Xentec HID's, Dynatek CDI, Warn skid plates, Intellitronix gauges, 2010 intake/cvt duct work and dust shield, RZR seats, Bestop folding windshield, full cab kit, rear cage and rear seats (4 seater)

Last edited by out west; 04-07-2014 at 09:38 AM.
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post #2 of 11 (permalink) Old 04-07-2014, 09:39 AM
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I'd opt for the inner sleeve, add the 10" piece with the base welded on. With the inner sleeve you could bolt them together. My self I'd plug weld it, and then finish weld the seam between the 2 parts. Keep in mind that I tend to over kill!!!!!!!!!!!!!!!!LOL

2009 700EFI XTX, , AC Winch, 2010 Dust Shield EPI Sport Utility Clutch Kit , Street Legal, Cage chopped 2 ", Aluminum Diamond Plate Trim, Relocated Factory Bladders with covers, 5 Pt. Harness installed, Bed Tiedown System, Scat Pro-Car Seats, Secondary Battery installed, Oil Pressure, Oil/CVT Temperature, Volt Meter & Water Temp Gauges installed with Dash Plate, Bighorns, ITP Black 212 Wheels. Tonneau cover. 750 Big Bore Kit, Web Cam, and Rocker Arms.

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post #3 of 11 (permalink) Old 04-07-2014, 09:43 AM Thread Starter
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Quote:
Originally Posted by Fairmont79 View Post
I'd opt for the inner sleeve, add the 10" piece with the base welded on. With the inner sleeve you could bolt them together. My self I'd plug weld it, and then finish weld the seam between the 2 parts. Keep in mind that I tend to over kill!!!!!!!!!!!!!!!!LOL
What do you mean by plug weld it RD (are you talking about welding the inner sleeve in)? If I go the inner sleeve route, should I still try and have both pieces as square as possible or not a big deal (weld will fill in any gaps)? I'm looking to avoid any bolting together. Really looking for a complete weld repair.

Name: Shane

-2011 Polaris RZR-4 800 (SOLD)
-1999 Polaris Sportsman 500 ATV
-2006 AC Prowler 650XT (SOLD)-- updated bevel gears, updated oil pump driven gear, 4 wheel disc brakes, line lock E-brake, Papa Slap clutch, Xentec HID's, Dynatek CDI, Warn skid plates, Intellitronix gauges, 2010 intake/cvt duct work and dust shield, RZR seats, Bestop folding windshield, full cab kit, rear cage and rear seats (4 seater)
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post #4 of 11 (permalink) Old 04-07-2014, 10:04 AM
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I think the correct term is rosette weld, but I drill 3/8" holes in the outer tube, then slip the inner tube in and using a high setting on my wire feed I weld through the holes. The ends are much better squared to each other, as it makes for a better fit, and finish.

2009 700EFI XTX, , AC Winch, 2010 Dust Shield EPI Sport Utility Clutch Kit , Street Legal, Cage chopped 2 ", Aluminum Diamond Plate Trim, Relocated Factory Bladders with covers, 5 Pt. Harness installed, Bed Tiedown System, Scat Pro-Car Seats, Secondary Battery installed, Oil Pressure, Oil/CVT Temperature, Volt Meter & Water Temp Gauges installed with Dash Plate, Bighorns, ITP Black 212 Wheels. Tonneau cover. 750 Big Bore Kit, Web Cam, and Rocker Arms.

Either - Dick or RD
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post #5 of 11 (permalink) Old 04-07-2014, 10:16 AM
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Quote:
Originally Posted by fairmont79 View Post
i think the correct term is rosette weld, but i drill 3/8" holes in the outer tube, then slip the inner tube in and using a high setting on my wire feed i weld through the holes. The ends are much better squared to each other, as it makes for a better fit, and finish.
x2 on rd's idea.

2015 A/C Sport,With a few add ons..........
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post #6 of 11 (permalink) Old 04-07-2014, 10:25 AM
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Quote:
Originally Posted by out west View Post
I'm going to repair my rear cage (well at least one of my novice welder buddies will be). Previous owner made the mistake and cut the feet off that mount in the bed. So I'm looking to have extensions welded on. Right now, the current feet are not cut square at the bottom. So I had some questions for you welders out there.

1. Should I take the cage off, try and cut the feet square, and just butt up new pieces to existing and have welded? Will that work, or do I need like a small inner sleeve to slide into both pieces at the joint? What would your typical welder do?

2. A friend brought up the idea of taking tubing and necking it up to slide over the existing 1 3/4" OD tube feet and then welding the two together (no worry if existing feet are square at bottom). What are your thoughts on this? Would matching 1 3/4" OD tubing work to stretch it out to fit over existing? If I go this route, I'll have to go to a machine shop to have them stretch the tubing as I don't have the equipment for that.

I have posted a picture of what I'm trying to repair.
I like that cage Shane.

2015 A/C Sport,With a few add ons..........
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post #7 of 11 (permalink) Old 04-07-2014, 11:50 AM
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X3 on RD's suggestion .. strongest and will allow a better weld , but I would also grind both sides of the tube with an angle grind [replacement and existing stub] to give you a V in the pipe to weld and filler then you have the best possible strength and alignment.

name is Gary or hey you if ya forget

2009 Prowler XTZ , couple things added here and there
'83 CJ7 / SBC + whole lot added here and there
'01 Dodge / Cummins / Dually, a ton of stuff added here and there

INSTRUCTIONS FOR THE NEWBIES ...
1. Bring in a good load of firewood for the pit
2. start the morning coffee , strong but not burnt / boiled down , IMPORTANT start it early as many of us old farts get up early !!
3. sit a spell and swap some lies with the best of us
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post #8 of 11 (permalink) Old 04-07-2014, 04:29 PM Thread Starter
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Thanks for the input guys. I'll look into doing it with the sleeve. Now just have to track down some metal tubing.

Name: Shane

-2011 Polaris RZR-4 800 (SOLD)
-1999 Polaris Sportsman 500 ATV
-2006 AC Prowler 650XT (SOLD)-- updated bevel gears, updated oil pump driven gear, 4 wheel disc brakes, line lock E-brake, Papa Slap clutch, Xentec HID's, Dynatek CDI, Warn skid plates, Intellitronix gauges, 2010 intake/cvt duct work and dust shield, RZR seats, Bestop folding windshield, full cab kit, rear cage and rear seats (4 seater)
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post #9 of 11 (permalink) Old 04-08-2014, 09:47 AM Thread Starter
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OK guys, one last question. The bottom of the feet will be threaded so I can install a bolt from underneath the bed into the feet of the cage. Should I just get a bottom plate thick enough to drill and tap some threads in it, or should I get a piece of metal and weld a nut on the inside to thread a bolt through? What would be the better method?

Name: Shane

-2011 Polaris RZR-4 800 (SOLD)
-1999 Polaris Sportsman 500 ATV
-2006 AC Prowler 650XT (SOLD)-- updated bevel gears, updated oil pump driven gear, 4 wheel disc brakes, line lock E-brake, Papa Slap clutch, Xentec HID's, Dynatek CDI, Warn skid plates, Intellitronix gauges, 2010 intake/cvt duct work and dust shield, RZR seats, Bestop folding windshield, full cab kit, rear cage and rear seats (4 seater)
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post #10 of 11 (permalink) Old 04-08-2014, 10:31 AM
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the bed your attaching to is plastic right ???

the larger foot you give it the better the support , and a sandwich plated above and below would be the way I'd do it , spread it as much as I could do it reasonably 4x4 at bare minimum 6x6 better

name is Gary or hey you if ya forget

2009 Prowler XTZ , couple things added here and there
'83 CJ7 / SBC + whole lot added here and there
'01 Dodge / Cummins / Dually, a ton of stuff added here and there

INSTRUCTIONS FOR THE NEWBIES ...
1. Bring in a good load of firewood for the pit
2. start the morning coffee , strong but not burnt / boiled down , IMPORTANT start it early as many of us old farts get up early !!
3. sit a spell and swap some lies with the best of us
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