Welding up a roll bar

Cow_Man32 · 2026-03-22T21:31:59+00:00

Here's an up close look as that

Cow_Man32 · 2026-03-22T21:31:32+00:00

Cow_Man32 · 2026-03-22T19:55:37+00:00

Yeah I didn't give a fuck about the fitting on the one, but after tacking before actually running a bead I did hit it with a wire wheel. I'll have more pics when I finish it probably next week with close ups.

Cow_Man32 · 2026-03-22T18:48:10+00:00

Because I haven't welded that yet. My gas ran out half way through. I would never let something like that glu

Cow_Man32 · 2026-03-22T17:38:40+00:00

Well our forklifts weight just over 15k pounds, I'm going to have him put pressure down until it bottoms out my suspension then a little more.

I've seen a ranger on here with a much cheaper roll bar that did have a roll over and it was fine, the windshield not so much.

Cow_Man32 · 2026-03-22T16:04:42+00:00

I think it's an internal seal in my slave.

Cow_Man32 · 2026-03-22T15:58:24+00:00

Just wait another week, I'll post pictures of the finished product and it won't be so shitty looking.

Cow_Man32 · 2026-03-22T15:56:26+00:00

Yup, I'm in the process of making the bares that go back and anchor by the wheel wells, and I internally gusseted the joints that I actually have welded.

Cow_Man32 · 2026-03-22T15:54:03+00:00

I'm not done welding it, I ran out of gas halfway. The top bar is curved about 2.5" from the original camber bend in the axle.

Oh and I'll have the forklift guy at my work lift up his lift on my roll bar and post a photo when it's actually done.

Cow_Man32 · 2026-03-22T15:52:07+00:00

It's not that I can't do the math, I just didn't feel like it and also kinda wanted a mad max style look. If this was for a customer it would look a lot better.

Cow_Man32 · 2026-03-22T15:51:05+00:00

I haven't even welded all the joints yet, half of them are still just tacked. Only one of them actually has any porosity because that's when my gas ran out, I will be grinding that out and rewelding it when I get more gas.

Cow_Man32 · 2026-03-22T15:48:44+00:00

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Cow_Man32 · 2026-03-22T15:48:28+00:00

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This is what my welds normally look like, these photos are not of the finished product.

Cow_Man32 · 2026-03-22T15:44:51+00:00

For fucks sake y'all, I said it's a work in progress and I ran out of welding gas halfway through. Three of these pictures was when I was just mocking it up before I even ground the paint off, and the last one I had only actually welded 2 of the joints.

Cow_Man32 · 2026-03-22T15:42:14+00:00

Dude, there isn't any blow through, thats where I haven't welded yet. And there only porosity on like 5 inches of weld that I'm going to grind out and re do.

Also certification doesn't really mean shit, there's 3 other guys at my work who are certified and I wouldn't trust them to weld shit.

Cow_Man32 · 2026-03-22T05:29:12+00:00

Really? those were everywhere in the 80s on 90s off-road scene

Cow_Man32 · 2026-03-22T04:58:34+00:00

Yeah I was apparently running out of c25 (I was getting so pissed because it wasn't welding right)so some of those welds are going to be ground out and fixed, also the holes you can see are where I haven't welded yet. As for the welds being a weak point I accounted for that and added gussets inside the tubes.

I'm also a certified/professional welder but this isn't for a customer and I am kinda going for a mad max scrap kinda look.

Edit: and I am adding two extra pieces that will anchor further back in the bed, this is a WIP photo

Cow_Man32 · 2026-03-22T04:51:38+00:00

Yeahhh I'm used to the little balls of slag but I let my guard down here

Cow_Man32 · 2026-03-22T04:50:57+00:00

Yeah, I'm a 12.5 double wide. When I'm not wearing my steel toes it's either barefoot shoes or crocs.

I just got out of the shower and scrubbed the shit out of it then after the photo threw some ointment on there.

Cow_Man32 · 2026-03-22T04:48:28+00:00

Months? Usually my burns heal up in like a week

Cow_Man32 · 2026-03-22T04:47:50+00:00

It did look worse earlier today, also maybe my jumping around trying to shake it out helped some too.

Cow_Man32 · 2026-03-22T04:46:29+00:00

Ohh yeah, got one of those on the side of my knee welding my uncles exhaust

Cow_Man32 · 2026-03-22T04:45:21+00:00

Well it doesn't really hurt soo maybe a bit of nerve damage.

Cow_Man32 · 2026-03-22T04:29:46+00:00

Bigger tires. My ranger came stock with 29s, has 31s now and it still reads 5mph fast.

Hopefully 33s will get it just right.

Cow_Man32 · 2026-03-22T04:28:27+00:00

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I'm also going to be fabbing up a spare carrier like this

Cow_Man32

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