800EX Rear Roll Cage Modification

Started by bezerk1, September 21, 2016, 04:49:55 PM

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bezerk1

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bezerk1
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I thought I'd share a few pics of my rear cage addition.  It took about 6 hours to bend and weld it together.  Once completed I painted it with spray on bed liner which matched the factory paint perfectly.  It is easily removable with a few bolts.  I did have to cut a small slit in the roof to allow it to bend over the new bars.  In the pictures I have the roof clamped and sitting in the sun so it contours in.  Enjoy.

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Quote from: bezerk1 on September 21, 2016, 04:49:55 PM
I thought I'd share a few pics of my rear cage addition.  It took about 6 hours to bend and weld it together.  Once completed I painted it with spray on bed liner which matched the factory paint perfectly.  It is easily removable with a few bolts.  I did have to cut a small slit in the roof to allow it to bend over the new bars.  In the pictures I have the roof clamped and sitting in the sun so it contours in.  Enjoy.
Man that's cool! Good job !!

NL800

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NL800
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Wow great job.
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gfmoto
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Nice work!!! How's it attached?
2015 ZForce 800EX
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Cosmosdan

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Cosmosdan
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I wish I wasn't a sucky welder.
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Too new for mods yet

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chuddly

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chuddly
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Yup looks very nice.  I plan on doing something similar.  How did you attach it to the roll cage and back end?
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bezerk1

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The bars are attached with 1 5/8 inch clamps that I ordered off of ebay.  The are made specifically for roll bars and suspension fabrication.  Hopefully you can see them in the attached picture.  The rear of the cage has tabs welded onto it.  I drilled and tapped new holes where the existing stainless bumper is attached.  The new cage fits snug on top of the existing bumper.  I was even able to reattach the rubber bumpers.

Coloradocrawler

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Coloradocrawler
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Very nice.
2019 Zforce 1000
Flip windshield, synthetic winch rope, 2 inch lift, lights, 30 inch tires, back window, snorkels with pre-filter on air box, harnesses, Super ATV box, door inserts, B2 clutch setting, desert craft seat springs, 3L fuel cell, Bluetooth stereo, Garmin
GPS,  chop coming soon.

2014 z600 SOLD

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Coloradocrawler

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Coloradocrawler
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Nice work...
2019 Zforce 1000
Flip windshield, synthetic winch rope, 2 inch lift, lights, 30 inch tires, back window, snorkels with pre-filter on air box, harnesses, Super ATV box, door inserts, B2 clutch setting, desert craft seat springs, 3L fuel cell, Bluetooth stereo, Garmin
GPS,  chop coming soon.

2014 z600 SOLD