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Offline chuddly

Zforce 800 Cage Chop
« on: February 13, 2017, 07:18:41 AM »
This weekend I decided it was time to cut down the stupidly tall roll cage that comes on these from the factory.  I am going to be racing mine this year so I have to fit in it with a helmet and I have a son who is 6'5" so I could not do an EXTREME cage chop on it and really get it down there.  I went with a 5" chop and that left plenty of room.  With me sitting in it (I'm 5'10") with a helmet on I still have about 3-4" above my helmet to the bottom on the roll cage bar.  In the picture with the red lines you will see where I took the chop out of.  It is a straight section of tube so that made it an easy cut and weld.  The center tube that was cut I completely replaced because it was only about 3 1/2" long after the chop so it was easier to replace it than to try to sleave it and weld it in.  The other 2 cuts were sleaved and welded in on the back portion of the cage.  The front legs of the cage did not have to be cut as there is enough adjustment in the front cage mount points that they will lay back.  this give you more "windshield rake" and also makes it so that any windshield will still fit a chopped cage.  Although I dont have it on I did put it on and the factory roof will still just fine with 2 washers for the rear most tabs.  I also had to cut the top tub just above the drivers head to angle the tube to get it to line up because the cage is narrower at the top.  You will see that in one of the pictures.  Also because we have a few of these carts around I pulled one into the shop directly behind mine and you can see side by side the difference in roof height and rake on the 2 carts.  It was not a bad chop at all.  I probably spent 4 hours total on it and that was cleaning up and shooting a quick coat of black paint on it to keep rust off.  If anyone has any questions feel free to ask.  Also I added a cross bar to the front of the roll cage.  I will likely add vertical bracing up to the top "halo" from that cross bar for extra strength but I just didnt get to it this weekend.








I can imagine a world completely at peace.  A world where there are no weapons, no war, and no violence at all.  And I can imagine us taking over that world because they would never expect it.

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Offline NMKawierider

Re: Zforce 800 Cage Chop
« Reply #1 on: February 13, 2017, 08:41:39 AM »
Nice work...much better!
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS| Bandit Springs

My Videos On YouTube

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Offline bezerk1

Re: Zforce 800 Cage Chop
« Reply #2 on: February 13, 2017, 09:13:20 AM »
Very nice.  It dramatically changes the appearance of the machine.

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Offline Derfer22

Re: Zforce 800 Cage Chop
« Reply #3 on: February 13, 2017, 09:25:35 AM »
Wow really liking the look!
2013 Z-Force 600
3" Lift
When in Doubt
Throttle it Out

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Offline chuddly

Re: Zforce 800 Cage Chop
« Reply #4 on: February 13, 2017, 12:13:19 PM »
Thanks guys.  I like the looks much better plus I think i will like the performance of a lowered cage.  Around here we have tight trails and trees.  I have MORE THAN ONCE leaned off camber and been rubbing the top roll cage bar on along a tree because the higher the cage the more it moves.  this should help with the scrubbing of trees.
I can imagine a world completely at peace.  A world where there are no weapons, no war, and no violence at all.  And I can imagine us taking over that world because they would never expect it.

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Offline NMKawierider

Re: Zforce 800 Cage Chop
« Reply #5 on: February 13, 2017, 01:37:58 PM »
Here's a question. With a little adjustment, can you still use the roof?
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS| Bandit Springs

My Videos On YouTube

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Offline chuddly

Re: Zforce 800 Cage Chop
« Reply #6 on: February 13, 2017, 05:32:47 PM »
Yes factory roof can be used if you get 2 washers. That is about it
I can imagine a world completely at peace.  A world where there are no weapons, no war, and no violence at all.  And I can imagine us taking over that world because they would never expect it.

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Offline Jason

Re: Zforce 800 Cage Chop
« Reply #7 on: February 18, 2017, 11:20:34 AM »
FINALLY somebody did one.  I've been wanting to see what this would look like for two years.  Well done chuddly it looks sharp.
2017 RZR XP 1000 Titanium Metallic

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Offline Wheels

Re: Zforce 800 Cage Chop
« Reply #8 on: February 18, 2017, 08:39:30 PM »
Great job, while your at the chop, add some gussets to reinforce that thin wall tube, Those Cages are scary.
If it has Pistons or Tits you will encounter problems.

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Offline NMKawierider

Re: Zforce 800 Cage Chop
« Reply #9 on: February 18, 2017, 10:21:53 PM »
Chuddly, can you give is a kinda step-by-step cut and bend instruction? I see one extra grind spot on your pics I was wondering about and I think you must have had to bend the tube somewhere to get the drop. And what welder & wire did you use ?
2015 Z Force 800 (53") EPS -
Custom Air Intakes | Custom Exhaust Mod | SuperATV Harness | Custom Fenders | Custom Skid/Rock Sliders | 27" GBC Grim Reapers | Seizmik Mirrors |Конструктор (Rodin's) Doors | Dr Pulley Sliders | 1.5" Wheel Spacers | BENZ Silencer (as needed) | SATV Flip Windshield W\ Rear Shield | Dual Light Bars | Diamond Plate Storage | Magellan TRX7 GPS| Bandit Springs

My Videos On YouTube

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Offline gfmoto

Re: Zforce 800 Cage Chop
« Reply #10 on: February 19, 2017, 12:06:15 AM »
Now THATS what these should look like!  Awesome job!
2015 ZForce 800EX
32" light bar
2-4" spots
Custom Cv guards
DIY 1/2 windshield
UNI air filter
DIY rear window
BOSS ATV 28. 450W speakers
Alpena Rock Lights (tough pods)

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Offline autorvshop

Re: Zforce 800 Cage Chop
« Reply #11 on: February 19, 2017, 09:32:41 AM »
HAS ANY ONE DONE  BACK BONES YET, MY SON AND I  CHOPPER MY CAGE A COUPLE OF MONTHS AGO, SAMES  THE ONE ABOVE IT DID MAKE A BIG DIFF, NOW I WHAT TO BUILD A SET OF BACK BONES THATS THE NEXT PRIOJECT, GOOD JOB ON THE CAGE CHOP, I ALSO WANT TO  X BARRED THE ROOF CAGE, TUBING IS A BIT SMALL ON ORIGINAL CAGE
« Last Edit: February 19, 2017, 09:34:14 AM by autorvshop »
2015 Z800 EX
IRON BALISTIC SKID PLATES
4600 LB WINCH  HOMEMADE BACKBONES
SUPER ATV FULL TILT WINDSHIELD
DUAL BATTERYS   CUSTOM AIR FILTER RELOCATION
42 IN LIGHT BAR, PLUS 4IN SPOTS
TWO BROTHERS EXHAUST
TWIN AIR FILTER
HOME MADE DOORS
TUSK INSIDE ROOF PACK
DOUGLAS MOAPA RUN FLAT TIRES 28  10 FT 12 REAR DOUGLAS STEALTH 8 IN WHEELS FRT, 10 IN WHEELS REAR
QUICK DISCONNECT FIRE EXT
RACKBOSS RACK AND PINION WITH UPGRADED TIRE RODS AND ENDS
EJK TUNER
PRO ARMOR 5 POINT BELTS
18 GRAM SELF MODIFIED DR. PULLEY SLIDERS
SECONDARY CLOCKED TO C2
RIVAL FRT AND REAR BUMPERS
MR RPM OIL FILTER ADAPTER

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Offline flash

Re: Zforce 800 Cage Chop
« Reply #12 on: February 19, 2017, 04:06:46 PM »
actually I'm in the process of building a complete upper cage now, with the rear
of the cage tying into the bumper, got it cut and framed up.
will have some pic's soon....
2015 800EX.     Bandit Shocks
Two Brothers.    EZ Steer power steering
UNIfilter
Dynojet
Super ATV half windshield
Rival front and rear bumpers
Super ATV high clearance A-arms
Custom rockslides
29 inch bighorns
Secondary clocked to C1
Конструктор doors
Custom roll cage
MTX Mudsys30 soundbar
Fuel bead locks

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Offline chuddly

Re: Zforce 800 Cage Chop
« Reply #13 on: February 20, 2017, 07:49:55 AM »
I started to type something up about the steps to cut it but it is so hard to describe each tube and cut that it would be a novel.  I will record short video tonight about where I cut everything and upload it.  I think that will be MUCH better for everyone.
I can imagine a world completely at peace.  A world where there are no weapons, no war, and no violence at all.  And I can imagine us taking over that world because they would never expect it.

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Offline Wheels

Re: Zforce 800 Cage Chop
« Reply #14 on: February 20, 2017, 07:25:23 PM »
Great work guys
If it has Pistons or Tits you will encounter problems.