Synergy 5223 User Manual

SYNERGY MFG. 870 INDUSTRIAL WAY, SAN LUIS OBISPO, CA [phone]

PPM-5223 JK 4 DOOR B-PILLAR CAGE TIE IN KIT

Version 1.1

GENERAL NOTES:

• These instructions are also available on our website; www.synergymfg.com.

Check the website before you begin for any updated instructions and additional
photos for your reference.

• This is a weld in roll cage kit, all welding should be performed by an experienced

welder with proper welding equipment

• This kit can be used by itself or in conjunction with PPM-5221-A and/or PPM-

5224-A; 4 dr rear cage kit.

• This kit works with either a soft top or hard top.

• Use extreme care when welding and grinding in the interior of your Jeep, remove

or cover any components you do not want welding spatter or grinding sparks to
damage.

1. Remove the hard or soft top, if using a soft top, remove the door surrounds.

2. Remove the sound bar, roll bar covering, and roll bar padding in the B-pillar area.

3. Lastly, remove the carpet in the rear seat passenger foot well area. (This may require
removal of front seats)

4. With carpet removed, reposition front seats (if previously removed) and take note of
any floor insulation in the rear passenger foot well area. Mark out a 4” box from the
edges of the flat portions of the floor near the B-pillar trim.

5. This area needs to be free of any floor insulation / sound deadening material before
we can fit the B-pillar floor plates. The easiest way to remove the floor insulation is
with a hammer and chisel. Using the chisel at a 30-45 degree angle to the floor, chip
away the insulation until it appears how it does in image 5.2 below.

Img. 5.2

6. Clean up any remaining high spots or thick spots of glue by sanding. A 3” air sander
works well for this.

7. Once the B-pillar floor plate can sit flat as shown in Img. 7.1 be sure it is positioned
up against the flat corners of the floor. Next, mark and drill four 3/8” diameter holes
through the floor.

Img. 7.1

8. Bolt the B-pillar floor plate to the body with the bushing mount plate on the underside
as shown. Use a washer under the head of the bolt and a flange nut on the underside.

9. Now, test fit the bushing isolated frame tie in by using the ½-13 x 5.0” long bolt
included in the kit.

10. Mock the frame tie in position and take note of where to remove paint on the frame in
preparation for welding. Do not weld at this time.

11. Next, we need to trim some of the factory B-pillar cross bar to fit the new B-pillar tie
in tube.

 Mark a line 5/8” in and 4” long as shown in the images below.
 **Note** these cuts were a minimum needed to allow us to fit a

tig torch in position for welding. Slightly more material may need
to be removed depending on weld technique used (Tig, Mig, Stick
etc.)