16. Each cut was then de-burred and dressed up with a grinder, to make sure it fit tight up against the intersecting bar.
17. Once the sides and windshield bars were cut, notched, and put back in the car, we measured everything one more time before tacking them in place.
18. Now we wanted to get the removable seat belt bar going. First we determined the height of the bar by installing the seat and making sure it was below the top of the drivers shoulder, and didn't interfere with things like the rear window cranks. Once we had our position, one side was tacked in place.
19. The machined end of the clevis was slipped inside one end of the tube, while the other clevis was pined to the tab with the provided Faspin. Then we brought the bar in to find out its proper length between the clevises.
20. The swing out bars follow the same sort of procedure, but we found a yard stick really helped us find the right angle and height to fit in the car and clear things like the window crank.
21. The inner area of the brackets for the swing out bars needed to be angled some, and a metal bit made quick work of the task.
22. One benefit of using a straight edge is it really helps keep the tabs on the same angle, to prevent the bars from binding. After getting the tabs tacked on, the swing out bars were fabbed up just like the seat belt bar.
23. The rear bars that go from the back of the main hoop down into the truck had one bend in them from CAC. Since we are retaining the rear seat, we wanted to add one more bend in the bars so they would not encroach into the passenger area as much. We had to go to a local shop and have them put in a 30-degree bend 20 inches back from the CAC bend.
24. After that they fit just the way we wanted. The rears look like an extension of the sidebars that follow the angle of the rear glass as they enter the package tray.
25. Once in the trunk they fall right onto our pre installed plate.
26. With everything tacked in place, we called in the welding skills of Jimmy Pett from 714 Motorsports in Westminster, California. Jimmy has years of welding experience, and was nice enough to bring his Miller Diversion 180 TIG to our shop and buzz our bars together with nice, pretty welds.
27. You just can't beat the look of a good TIG weld.
28. The Alston cage also comes with pre-made gussets that can be installed at all the corner joints to add even more strength. Also, gussets are used in the areas where the pipe could not be completely welded all the way around, so if there is a short little part of the joint that can't be welded, the gusset will take up that slack, so to speak. After all the joints cooled we cleaned all the bars and shot a quick coat of sealer on them to prevent rust, until we decide what color to spray the cage. We are thinking black of course, but we'll do that when we are closer to being finished.