I'm not any expert on cages, rollbars, etc.. BUT...and I'm trying to ease into the answer.....DO NOT USE SQUARE TUBING FOR ROLL-OVER PROTECTION. I'll let a few of the experts pipe in with the fine details, but square tubing does not have any where near the strength of DOM round tubing, and square tubing will bend or FAIL if impacted...just about anywhere... a rollover is a much more violent event than a rock hitting a slider... the forces are MUCH greater, so the design and material of a roll structure must have that criteria FIRST...appearance LAST...Anyone done this yet? Someone asked me about it tonight, which then sparked some curiousity as to what it actually would look like. Basically, Im just thinkin of the same type of square tubing which is used for rock sliders. Any pics, any ideas?
You can bend square tube you just need the right dies. JD2 offers die sets that bend square tube. I personally would not use it, but it would probably work. I would only build an internal cage for a tacoma type of vehicle with 1.5 x 1.20 wall DOM myself anything else is overkill.
That stuff is going to weigh a ton, and IMO look like crap. Go with round tube.When I was thinking of a roll bar using square tube, I was thinking in a larger scale of tubing. That looks to be 2x2 steel, while I was thinking more along the 3x5 or 4x6.. resembling a similar design as a standard roll bar for the truck bed. Oh well, this was just a thought which arose after another Tacoma enthusiast asked about whether to buy a roll bar, or to have one made.