Rollcage/air jacks

So i finished making the last three gussets for the door bars and have got them about 50% welded in.

Then I kind of got distracted with my next job, mounting the front air jacks.

I wanted to get the front jacks in place before i welded in the rollcage tubes that pass through the firewall to the front strut towers.

The reason for this was that it would give me more room to work with up in the front footwell area where the jacks are going to be mounted.

Heres a run down on some of the work involved in mounting the front jacks:

First up i marked and cut out the area of sheetmetal that needed to be removed.

Both the outer and inner sill were cut out to make room for the jack.

Capped off the inner sill to retain its strength.

Bent some 16gauge sheetmetal around a piece of 4″ pipe and checked how it fit.

Welded a top piece on.

Trimmed to fit, welded in, then cut some mounts for the jacks and tacked them in place.

Tucks up nicely behind the front guard, will just have to cut a hole for the jack to pass through when aired up.

I’m going to weld a tube between the two mounting plates for strength. The jack will have two collars above the top plate and two below the lower plate, not sandwiching the plate like it is in the pictures. I’m having a hard time finding some 2.75″ thin wall tube in NZ, seems as though the sizes jump from 2.5″ to 3″. Might have to look at getting some shipped from America.