Roadless Gear, LLC

Installation Instructions for Suzuki Cages

Front add-on installation

Remove sun visors
Fit driver's side hoop leg behind side defrost vent

Remove passenger side defrost vent with padded needle nose pliers

Push passenger side of front hoop into position
Position top of hoop against rear view mirror stem as shown

If necessary, spread or squeeze hoop legs at base so they rest against sill wall of body using screw jack, ratchet strap, Hi-lift, etc.
Place one mount plate under the bottom of each leg on the floor, centering the leg base on it. Bent up tab on mount plate indexes between raised ridges on inner rocker panel

Weld these to the hoop legs once you are happy with their position
Position the top connector bars with the forward marked pre-notched end against the middle of the bend at the top of the front hoop. Note that these bars are notched to fit perfectly with no gap when placed in the correct position
If you do need to shorten the connector bars, do it from the rear-most end of the tube. This can be easily done with a hand grinder, a bench grinder, a hacksaw, whatever
Have all connections fully welded by a competent welder
Drill 3/8" hole through the floor to match the holes in the base mounting plates, then position the extra mounting (doubler) plates under the floor. (note that you may drill the holes prior to welding if you wish)

Install bolts from the top through both plates and tighten them
Weld the tubular corner gussets at the inside front corner where the top connector bars meet the front hoop.

Davesport Main Hoop and Rear Stay Installation for Soft Top Samurai

Bolt the new main hoop into place using the original hardware centering and aligning the hoop as you tighten the bolts
Remove the fuel filler neck cover plate and place the right main hoop diagonal support bar into place with the body mount plate right behind the fuel filler neck. When the bar is properly placed, it will be resting against the bump on the inside vertical bed (note that the cover plate may be reinstalled after cutting a small semi-circular notch out of the top)
Place the left support into place with the mounting plate cutout against the body relief in the right rear corner, and the bar will be the same distance from the top bed side as the bar on the right side is from its bed rail--approximately 3/4"
Make certain the top of the support bars are placed symmetrically from side to side on the main hoop and weld them into place
Mark and drill 3/8" holes in the body for the rear mounting plates. You may either drill through the plates, or unbolt the main hoop and remove the cage for ease of drilling these holes. Bolt the cage back in

Rear add-on (Family bar) Instructions

Full Height and add-on rear bar

Remove the fuel filler neck cover plate and place the right main hoop diagonal support bar into place with the body mount plate right behind the fuel filler neck. When the bar is properly placed, it will be resting against the bump on the inside vertical bed (note that the cover plate may be reinstalled after cutting a small semi-circular notch out of the top)
Place the left support into place with the mounting plate cutout against the body relief in the right rear corner, and the bar will be the same distance from the top bed side as the bar on the right side is from its bed rail--approximately 3/4"
Make certain the top of the support bars are placed symmetrically from side to side on the main hoop and weld them into place
Mark and drill 3/8" holes in the body for the rear mounting plates. You may either drill through the plates, or unbolt the main hoop and remove the cage for ease of drilling these holes
Bolt the cage back in

Additional notes for add-on rear bar

Fit rear hoop to 'knees' or bends at the rear of the diagonal support bars with base of hoop tubes approximately 1" above bed/tailgate level. Use clamps (hose clamps work well) to hold it in position. Be sure top surface of rear hoop is parallel, or level, with main hoop
Place main hoop to rear hoop top connectors in place, making sure they are parallel, or level, with each other and tack weld all pieces in place. Note: Top connector bar should meet at top of diagonal brace where it attaches to main hoop
Make final measurements and adjustments as necessary before final welding

Hard Top Samurai Installation

Pull up carpeting in rear of vehicle and locate dimples in the rear fender-wells
Drill these dimples out with a 3/8" drill bit. This is where the main hoop mount plates will bolt on
Bolt the top main hoop mount plates through the fender-well and through the supplied back-up plates on the underside of the fender-well, but leave the bolts loose
Work the main hoop into position from the rear of the vehicle (you may need to remove the inner window guards to do this. It is much easier to weld the bars into place if you also remove the rear side windows)
Center the base of the main hoop on the mount plates and place a small tack weld on each tube on the inside, or nearest to the centerline of the vehicle, aspect of the tube/mount plate. This will allow a small amount of 'adjustment' fore and aft during the next phase of the installation
Remove the fuel filler neck cover plate and place the right main hoop diagonal support bar into place with the body mount plate right behind the fuel filler neck
Place the left support into place with the mounting plate cutout against the body relief in the right rear corner, ensuring the bar is the same distance from the side panel (or bed rail) as the bar on the right
Make certain the top of the support bars are placed symmetrically from side to side on the main hoop and weld them into place
Mark and drill 3/8" holes in the body for the rear mounting plates
Bolt the rear supports down
Finish welding any tacked connections
Now follow the instructions above for the installation of the front hoop (note that you may need to remove the steering wheel to get the front hoop in to position)

General Installation Tips and Tricks

Remove as much of the interior as possible. This limits the amount of damage and fires that will result from welding. DON’T FORGET TO WATCH THE UNDERSIDE OF THE VEHICLE FOR FIRES TOO!
Use a clean piece of cardboard in between headliner and area being welded for protection
Keep a water bottle handy to quickly extinguish spot fires in undercoating or whatever

This product is not intended to prevent injury, death, or property damage in the event of an accident or crash. It is sold as an appearance item only. Provide appropriate padding over the cage in areas that you or your passengers may come into contact with, especially in areas near where your head is!