All-Pro Off Road Roll Cage Short Cuts

| Toyota Reviews | Toyota Section | |

By: Harry Wagner. 10/2004

The interior had already been stripped before we started.
The All-Pro kit comes complete with everything you need.

Most organized events require participants to have a roll bar in their vehicle, or a fixed hardtop. This requirement means that a roll cage has never been manditory for my Toyota pickup. Does that mean that a roll cage is not necessary in a Toyota? Well, these same events often specify at least one locker and 33" tires as well, indicating the difference between "good" and "good enough".

My truck was built to tackle the most difficult trails, and after seeing the potential for multiple rollovers at destinations like Moab and Colorado, I considered a roll cage a personal requirement. I am not particularly fond of exocages, as they tend to add considerable weight and air resistance to the vehicle as well as extra width that can become a limiting factor on tight trails. An in cab cage would work best for me, but there are limitations with these as well. Toyota pickups are not spacious to begin with, and adding tubing has the potential to render speakers, window cranks, and wing windows unusable.

Start by determining where the floor plates will be mounted.

Fortunately All-Pro Off Road offers a roll cage kit for Toyota pickups and 4Runners constructed out of 1.5" .120" wall DOM tubing that closely follows the contours of the Toyota cab. It is my opinion that this is the best cage available for Toyota pickups, offering custom fabrication at a mass produced price. The cage comes pre-bent but disassembled, so welding and notching are required. All of the bars are shipped slightly oversized to provide a custom fit once sized to your cab.

The tubes were notched for tight fitment.

The cage kit arrived quickly, leaving me just enough time to buy a tubing notcher and download instructions from All-Pro's website. The notcher is just a cheapo model purchased from Harbor Freight. If I planned on doing a lot of tube work I would invest in a higher quality piece of equipment, but for this job the Harbor Freight notcher was adequate. Since the interior of my truck was already gutted, my father and I started by determining where we would place the feet of the bars. Once these locations were marked we removed the sound deadening material and drilled holes in the floor of the cab. Next the bottom of the rear hoop and the two bars that run front-to-rear were trimmed so that they fit flush on the plates at the floor of the cab. Once the bars were in the proper location they were then tacked in place.

Everything was tacked together in the cab, then removed and fully welded.

The completed installation hugs the cab well as to not take up valuable space.
Padding was added to the side bars since they are in close proximity to my head.

Two bars must be welded to the rear hoop that butt against the front bars and are connected with sleeves. These bars were notched and trimmed to fit flush with the front bars and then tacked in place. The sleeves were added at this time to mark where the necessary holes were to be drilled. Similarly, there are two bars that span across the top of the windshield and are connected by a straight piece of tubing and two more couplers. These pieces were also notched, tacked, and marked for drilling. All-Pro includes a center spreader bar, however I chose not to use this bar since I did not feel that it added much in the way of strength to the overall design. Instead I included a bar across the rear hoop just below the window to provide more lateral support in the event of a hard side impact.

With all of the pieces tacked in place, the entire cage was removed and fully welded. The holes for the sleeves were also drilled at this time and I spray painted the cage semi-gloss black. Once the paint was dry my father and I reinstalled all of the pieces and bolted it together. Be sure to note which sleeve goes in which location, since they are not all drilled exactly the same. I am pleased to report that the cage does not interfere with the wing windows or window cranks on my truck. I capped off the installation with rollbar padding on the side bars and mounted a fire extinguisher on the rear bar. Now I am better protected on the trails, all without giving up much in expense or interior space.

Contacts Related Links
  • All-Pro Off Road
    Department 4x4Wire
    541 N. Palm Ave
    Hemet, CA 92543
    Telephone: (909) 658-7077
    Web site: All-Pro Off Road

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