ATV Cage Attempt

[deephis46]

First of all, I like how UTV looks like, like a Can-Am Maverick's. Looks sick!! (Hopefully I can afford one in the future)
So I made this cage for Baja 5B, started few months ago but only have these pics.





Actually, I have weld some flange nuts that are ready for panels.

Need to complete :
- Panels.
- Some more braces.
- Paint the cage and panels.

Will take more pics later...

Let me know what you think.

Thanks

[CraftWerks-RC]

Looks good... did you get any more work done to it?

[deephis46]

Not much to do with it but last month (maybe, not sure), I added the panel mounts. And on last Sunday I put new tires and wheels. This is what it looks like right now.





Hopefully tomorrow I can work for the panels. Panels would be fiberglass.

[king quarterscale]

Make the panels out of ABS sheet. Quick and way cheaper than fiberglass sheet. Or 1/16-1/8 lexan sheet. Fiberglass will add more weight just as the tube frame did. Weight is a killer for speed.

[deephis46]

My plan is want to add some contour to the panels, so I think I will make with fiberglass + resin but I will make it as lighter as possible.

[king quarterscale]

With ABS or lexan sheet you can use heat and make bends and contours. Fibeglass is messy and expensive and require more work. The only good fiberglass is epoxy resin ( West system for large areas or Pacer finishing resin for small repairs ). NOT the fiberglass you buy at the auto parts store. It is polyester resin JUNK!

[deephis46]

How if the contour on the middle of ABS sheet? Using a vacuum form tool? Or any other options maybe?

Indeed, I have made panels for another cage and messy to make one. But I only make the mold just from one plywood sheet then lay down the fibers on it then smear the resin. After dry trim the excess. Surface is not really smooth, needs sanding (inner surface is smoother thats touching cage, outer surface not smooth).

[king quarterscale]

To heat ABs sheet use a heat gun or propane torch. It will work for small bends. Bigger parts use oven and a cookie sheet non stick or with aluminum sheet with a mold. Heat the plastic until it bend s or sags and then place it on the mold and hold it down until it cools. It all depends on how much contour you need. It takes some practice but works good. Lexan requires a lower heat to bend and contour. I usually just cut Lexan and make panels. Be creative???

[deephis46]

Never been using ABS sheet but looking at youtube it actually needs to vacuum to not to have a crimple. But I will give it a try.

[king quarterscale]

Originally Posted by deephis46

Never been using ABS sheet but looking at youtube it actually needs to vacuum to not to have a crimple. But I will give it a try.

I use ABS sheet and only do bends. So depending on how much you want to contour ???? I use a propane torch and heat the plastic until it is soft and bendable. You will be using 1-8-3/16" material. You can experiment with it and see if you like it. What your trying to do you don't need to vacuum form. Just make panels and some contours.

[deephis46]

Here is last build with fiberglass panels,





It was 6 layers of fiberglass. Still not that heavy though.

I haven't got any ABS sheet but I have the resin left over from that build. I don't know but I think I'm going to use the resin from it.

This is what I'm after,



It's extruding (emboss).

[king quarterscale]

You should have no problems with ABS sheet bending to those shapes. Its quicker and cheaper You can use the same forms and heat the plastic to bend. over and over. With fiberglass you need to gel coat the outside to make it smooth or lots of paint layers (1/16" fiberglass and 1/16" gel coat). 1/8" ABS should be fine. To attach to the frame I use zip ties and drill holes in the ABS near the frame.

[deephis46]

Just finished all panels….



Made from polycarbonate sheet.

[king quarterscale]

Better choice of material but metal fasteners with plastic sheets is disaster down the road. The holes for the fasteners should be 1/32 larger and use plastic washers to hold down. Abs sheet I have found to be a poor choice for material. It will crank and shatter if fixed to the chassis. I use zip ties to hold the material down. It needs to be flexible to move a little. For fiberglass you need to use epoxy resin (West system). Not that polyester type you fine at the hardware store.