Poison Spyder LJ FULL CAGE KIT User Manual

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LJ FULL CAGE KIT INSTALL

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Thank you for purchasing a Poison Spyder Full Cage Kit for your Jeep TJ Unlimited (LJ). Poison Spyder’s innovative Lazer-Fit technology provides for the easiest, fastest installation of any aftermarket full cage kit on the market. Installation does require specialized skills and

tools, such as welding. If you are not condent

in your mechanical skills, please seek the help of a professional to perform the installation. Please read through these entire instructions before proceeding with installation.

PARTS LIST

Please check your packages immediately upon arrival to ensure that everything listed is included, and to check for damage during shipping. If anything is missing or damaged, call Poison Spyder at (951) 849-5911 as soon as possible.

(2) Windshield Mount Plate L&R

(2) B-Pillar Mount Plate L&R

(2) C-Pillar Mount Plate L&R

(2) Lower A-Pillar L&R

(2) Main Side Hoop L&R

(2) Upper A-Pillar Tube L&R

(2) B-Pillar L&R

(1) Dash Bar

(1) A-Crossbar

(2) Forward Stringer L&R

(1) B-Crossbar

(2) Rearward Stringer L&R

(1) C-Hoop

(2) C-Pillar L&R

(1) Seatbelt Bar

(1) Rear Stringer Spreader Bar

1113

(2) 1/2-13 X 2-1/2 Gr8 Hex Head Cap Screw

(2) Washer Plate

(2) 1/2-13 nylon insert lock nut

TOOLS NEEDED

• Mechanic’s tool set including Torx bit set

• T-50 “Tamper-Proof” Torx bit

• Ratchet straps

• Welder and proper welding equipment

• Protective welding blankets

INSTALLATION INSTRUCTIONS

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INSTALLATION NOTES

The Full Cage Kit will work with the factory

Jeep soft top. The sound bar can be modied (read: ‘cut up’) to t. Duster rear deck covers,

“windjammers” and short stile bikini tops will work. However, “safari” style bikini tops will not

t. Children can ride in the back seat but the

Poison Spyder Full Cage Kit was NOT designed to accommodate adult passengers in the OE back seat.

Installation of the Full Cage Kit can take up to 8 hours. This kit requires welding, which should be

done by a certied welder. You will need a friend

or two to assist with the installation. A good set of Torx bits is required for removal of the factory cage, including a T-50 “tamper-proof” Torx bit.

IMPORTANT: It is imperative that the top, doors, seats, plus any other components that are going to be reinstalled after the cage install be test-

tted BEFORE nal welding of the cage! Poison Spyder Customs is not liable for tment issues

due to negligent install.

REMOVAL OF THE FACTORY CAGE

1. Park vehicle on a level surface and set the emergency brake. You will want to wear eye protection beyond this point.

2. Remove the front factory spreader bars from the cage main hoop and the windshield. Save the four bolts that were used to fasten the bars to the windshield (two on each side), they will be re-used later.

3. Remove the factory roll bar from the vehicle. Be careful to not strip the Torx bolts, as they will be re-used. Remove the seatbelts from the roll bar.

4. On Jeeps with factory soft tops, remove the soft top brackets located on the factory roll bar. These can be re-attached to the new roll bar.

5. Inside the body tub on each side, there are triangular-shaped sheetmetal tabs that the factory roll bar mounted to using the tamperproof Torx bolts. Cut these two pieces off.

6. Along the front of the door jamb, there are three Torx bolts positioned in a vertical line,

going into the rewall.  Remove all three

bolts from both sides.

LJ FULL CAGE KIT INSTALL

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FIGURE 1

INSTALL PROCEDURE

NOTE: Throughout these procedures, refer to the assembled cage diagram at the top of Page 3

for reference identication and in proper general

orientation of cage components. In most cases, the laser-cut notches and laser-etched assembly marks will eliminate all guesswork. Regardless, carefully inspect each part and its placement

prior to tacking and nish-welding. Also, each

step should be extrapolated for both sides, where any procedure is to be duplicated on both sides of the cage. Also NOTE that the photos depict an installation in a TJ. The LJ installation is identical with the exception of the shape of the rear stringer bars and the addition of the Rear

Stringer Spreader Bar.

1. Clean ALL bare metal pieces provided in the kit, using a clean rag and brake cleaner. This will ensure an easier, cleaner installation and better welds later in the installation.

2. Install the Windshield Mount Plates L&R

on either side of the windshield, using the factory hardware that held the OE spreader bars in place.

FIGURE 2

INSTALLATION INSTRUCTIONS

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LJ FULL CAGE KIT INSTALL

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3. Install the B-Pillar Mount Plates L&R 2 in the locations where the main hoop of the factory roll bar bolted in, just behind the door opening on either side. Re-use the factory hardware.

FIGURE 3

4. Install the C-Pillar Mount Plates L&R 3 where the factory roll bar bolted in at the rear corners. Orient the plates with the rounded point edge facing the rear of the Jeep. Secure them using the OE hardware.

FIGURE 4

5. Weld the gusset seam on each of the Lower A-Pillars L&R 5. This seam was left un-welded so that you may weld it to match the weld style of the rest of your cage. For instance, if you are TIG welding your cage, you would likely prefer to have your own TIG weld in such a highly visible spot as this.

INSTALLATION INSTRUCTIONS

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LJ FULL CAGE KIT INSTALL

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FIGURE 5

6. Install the Lower A-Pillars L&R 4. Bolt each Lower A-Pillar into place using the three Torx bolts you removed during Step 5 of the Factory Cage Removal process. Note that once installed, the Lower A-Pillars will NOT be oriented perpendicular to the Jeep. They will angle slightly inward. Be sure to

test-t the doors for proper closing, before

proceeding.

FIGURE 6

7. Install the Main Side Hoops L&R 6, one side at a time. Have a friend hold the Main Side Hoop in place with the front portion of the tube in contact with the Windshield Mount Plate, with the tube end centered on the plate. Hold the rearward end of the tube so that it lands centered within the curvedpoint area of the C-Pillar Mount Plate. Tackweld the Main Side Hoop to each plate

FIGURE 7

8. Install the B-Crossbar 12 between the two

Main Side Hoops. Reference the laseretched markings to correctly locate the C-Crossbar along the inner side of each Main Side Hoop.

FIGURE 8

9. Install the B-Pillars L&R 8 between the

B-Pillar Mount Plate and the Main Side Hoop on either side. Reference the laser-etched markings to correctly locate the B-Pillar tube along the Main Side Hoop. Tack the B-Pillar into place.

10. Install the A-Crossbar 10 and the Forward

Stringers L&R 11 at the same time. Have a friend help with holding the three pieces

FIGURE 9

INSTALLATION INSTRUCTIONS

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LJ FULL CAGE KIT INSTALL

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in place. Start by holding the A-Crossbar in place between the two Main Side Hoops, toward the front of the Jeep. Next, hold the two Forward Stringers in place between the A-Crossbar and the B-Crossbar. Use the laser-etched marks on each of the tubes to properly locate the tube junctions. Use the Forward Stringers to locate the A-Crossbar the proper distance forward from the B-Crossbar. While holding them in place correctly located, tack the A-Crossbar and Forward Stringers into place. Ratchet straps may be useful in holding everything together while aligning and tacking.

FIGURE 10

11. Install the C-Hoop 14 and the C-Pillars L&R

at the same time. Have a friend help with holding the three pieces in place. Start by holding the C-Hoop in place, extended rearward from the downward bend on each Main Side Hoop. Next, hold the two C-Pillars in place vertically between the C-Hoop and the lower ends of the Main Side Hoop. While holding them in place correctly located, tack the C-Hoop and C-Pillars into place.

bends of the C-Hoop. Use the laser-etched assembly marks to properly locate and align the tube junctions. While holding these in place, also insert the Rear Stringer Spreader Bar between them. Tack weld all of these pieces once they are properly aligned. Note that the image below depicts a TJ, which differs slightly from the LJ in terms of the shape of the Rearward Stringers, and it also does not show the Rear Stringer Spread Bar.

FIGURE 12

13. Install the Upper A-Pillar Tubes L&R 7 and the Dash Bar 9 at the same time. Have a friend help with holding the three pieces in place. Start by holding the Upper A-Pillar Tubes in place between the Lower A-Pillar and the Main Side Hoop. Next, hold the two Dash Bar in place horizontally between the C-Hoop and the lower ends of the Main Side Upper A-Pillar Tubes. Use the laser-etched assembly marks as guides to properly locate the tube junctions. While holding them in place correctly located, tack the Upper a-Pillar Tubes and Dash Bar into place.

FIGURE 11

12. Install the Rearward Stringers L&R between the B-Crossbar and the inside

14. Install the Seatbelt Bar 16 to the rearward

side of the B-Pillars. Use the laser-etched assembly marks as guides to properly locate

FIGURE 13

INSTALLATION INSTRUCTIONS

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the tube junctions. If using custom seats and belts, you may adjust the height of the Seat Belt Bar (ignoring the laser etched assembly

guides)toproperlylocateitforyourspecic

setup. Tack the Seatbelt Bar into place.

15. Install any optional equipment at this time, such as Entry Grab Handles, Seat Belt Bung Kit, etc.

16.Fullytest-t all equipment that is located within, near or around the cage or any portion of the cage. This includes soft tops, doors, seats, etc. Test each component for

both t and operation.  It is EXTREMELY IMPORTANT that you verify proper tment

of all components at this time. If any tube placement needs to be adjusted, it is a simple matter of grinding the small tack welds to make any adjustments. Making these adjustments will be impossible once the cage is fully welded.

17. Finish-weld each joint in the cage. Before you begin, you may wish to place welding blankets or some other suitable protection for your Jeep’s interior. You may not be able to easily reach every area you need to weld while the cage is still installed in the Jeep, but we recommend doing as much as you can while the Cage is still in the Jeep, to discourage deformation during welding.

LJ FULL CAGE KIT INSTALL

FIGURE 14

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FIGURE 15

18. Remove the cage from thevehicletonish

any welds that couldn’t be reached before.

FIGURE 16

19. Paint or powder-coat your cage to protect it from rust. If painting it yourself, use a good quality self-etching primer on the bare steel of your cage prior to painting in the color of your choice.

20. Re-install the cage into the Jeep and properly tighten all fasteners. Use the supplied 1/2-13 Gr8 hex head cap screws, washer plates and nylon-insert lock nuts to secure the bottom foot of each Lower A-Pillar

to the existing hole in the oorboard of the

Jeep.

Congratulations, you have completed the

installation of your Poison Spyder Full Cage Kit!

INSTALLATION INSTRUCTIONS

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WARRANTY

Poison Spyder Customs™ warranties all of the products we sell and distribute for one (1) year from the date of sale. These products will be free from defects in material and workmanship

under normal installation, and use. Due to the intended use the powder coat nish is warranted for ninety (90) days. The nish warranty will not

cover a product if it has been damaged in any way. Warranty is limited to repair or replacement. Poison Spyder Customs™ does not offer any type of labor or shipping allowance and all warranty claims are subject to inspection by Poison Spyder Customs™.

At the discretion of Poison Spyder Customs™, the products in question can be repaired or replaced when found defective. Prior to any replacement or repair, written authorization must be obtained from Poison Spyder Customs™. Failure to contact us prior to having warranty work preformed will immediately void all applicable warranties; and it is then the sole responsibility of the customer to remit any payment incurred.

The warranty expressed above is the sole warranty of Poison Spyder Customs™, and any other expressed or implied warranties are

hereby specically excluded and disclaimed.

HOLD HARMLESS AGREEMENT

1. In purchasing a Poison Spyder Customs

Product™ I release, waive, discharge and

covenant not to sue Poison Spyder Customs

ofcers, servants, agents, or employees

(hereinafter referred to as Releasees) from

any and all liability, claims, demands, actions

and causes of action whatsoever arising out

of or related to any loss, damage, or injury,

including death, that may be sustained by

me (or anyone else), any property belonging

to me (or anyone else), whether caused by

the negligence of the releasees or otherwise,

while working on, using or any activity related

to this product.

2. I am fully aware of risks and hazards connected

with the use of a this product and I elect to

voluntarily engage in such use of this product

knowing that the use may be hazardous to

me and my property. I voluntarily assume full

responsibility for any risks of loss, property

damage or personal injury, including death,

that may be sustained by me (or anyone else), or any loss or damage to property owned by me (or anyone else), as a result of using this product, whether caused by the negligence of releasees or otherwise.

3. I further agree to indemnify and hold harmless the releasees from any loss, liability, damage or costs, including court cost and attorney fees, that they may incur due to my use of a this product, whether caused by negligence of releasees or otherwise.

4. It is my express intent that this Release and Hold Harmless Agreement shall bind the members of my family and spouse, if I am alive, and my heirs assigns and personal representative, if I am deceased, and shall be deemed as a release, waiver, discharge, and covenant not to sue the above named releasees. I further agree that this Waiver of Liability and Hold Harmless Agreement shall be construed in accordance with the laws of the State of California.

By accepting this product, I acknowledge and

represent that I have read the above Waiver and Liability and Hold Harmless Agreement, understand it and accept it voluntarily as my own free act and deed; no oral presentations, statements, or inducements, apart from the foregoing written agreement, have been made; I am at least eighteen (18) years of age and fully competent; and I execute this Release for full, adequate and complete consideration fully intending to be bound by same.

If you do not agree with the preceding Hold Harmless Agreement, you may return the product and receive a full refund. Please, contact a Poison Spyder Customs™ sales representative and they will issue a call tag for the product in question. Once the product has been received by Poison Spyder Customs™ a full refund will be issued.

INSTALLATION INSTRUCTIONS

Poison Spyder LJ FULL CAGE KIT User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual