Outer Limits 4x4 Board

Just chasing a few people’s personal opinions, in the near future I plan to build an exo cage on to my 91 SWB hardtop sierra. But the thing I am debating is whether or not to take out my 2 inch body lift. The reason for this is I want to try and keep a low COG and with all that extra bar work I think it might be worth while to try and keep it all 2inches lower. At the moment I am running about a 1 inch leaf lifted, 2 inch body lift on 31 inch tires with -27mm off set rims, I find at the moment my COG is really good and would like to keep it that way.
The problem I am face in taking out the body lifted is that not only will I have to do a virtual lifted on the guards for tire clearance, I think I may also run in to problems with bonnet and tunnel clearance because I am running a vit g16a bottom end with swift gti head and finally my transfer in raised 32mm to clear my custom chassis cross member. I can over come all these problems with a bit i.e. a lot of work. I am just wondering whether or not all that work is worth while for the benefits I will gain in a lower COG.
Also finally a internal cage is not an option at the moment due to needing all the space in the back to fit my BMX bike as this car is still going to be my daily.

Thanks guys

1) are exo's legal on the road where you are, and if so do they need to meet certain requirements?

2) is the exo for rollover protection or body protection? if body only then a lighter, thinner tube can be used cos it will most likely just take some "scrubbing" rather than the full weight of the zuk on it - so less weight.

3) you're going to create something to get snagged on and scrub on stuff, sometimes an exo just gets in the way =)

I used to fit my BMX in the back of my zuk with plenty of room for a roll bar still... although my bike is a 19" flatland bike, so i had a size advantage!

For all the work involved, how about a reese hitch on the back to hold a bike rack when needed, and a rollbar in the tub?

I am in QLD and the cage will fall under a ladder rack / roof rack, I think I will just put a few stickers on saying such and such roof rack co. The main purpose of the cage/ ladder rack will be to protect against panel, window damage also occupant protection for small, slow hill roll over’s. I know a exo cage is no where near as good as a internal 6 point cage with cross bracing when it comes to high speed rolls but I do believe a well designed and fabricated exo cage is better than no cage at all.

I do expect that it will get snagged from time to time but I will be making it as snug to the body as possible with out it being so close that it will flex on to the body. With the tube thickness and size I was planning on using 44mm o/d nominal wall thickness pipe for the main hopes and 38 for roof bars and bracing, but I am still undecided.

I do think I could fabricated a internal 6 point so I could just get one bike in, but I do regally put two bikes in at the moment. Also I do like the option of still being able to put four seats in. Lastly I am not a fan of leaving my bike on a bike rack just for security reasons, to much money to leave out in full view.
Thanks for the input.

the only flaw it what you wrote relates to security - in the back of the zuk or on the back of the zuk, its easy pickings either way =) haha theyre not renowned for their security!

screw the COG and just use the exo...

yea that is ture about zukes being as hard to break in to as a packet of smartys, but i think out of sight out of mind is allways a good security measure

Dunno about you blokes, but I never park my zook without my grizzly bear in the back, seems to deter thieves, if only they knew he is the kodiak kitten, would lick you to death...

i used to cart my bikes around in both my zuks,even fitted my 24" traildigger in my 89 swb hardtop.Don't know how much room you'd have to play with having any sort of internal hoop or cage.The exo will solve your bike problem but maybe create cop problems?i have a exo on mine that follows the body real close(too close in one spot ) and i wouldnt say it gets caught up or in the way ever,if it is in the way for some reason it is pipe after all,a little scrub wont hurt.Better than the body work i say.

Good luck with it all.

also mine has more lift than you and with a bodylift and all i dont find it any worse than it was before mate.There is still steelwork added down lower on the vehicle too,keeping some balance.

PJ,it is wierd for me reading some threads at times on zuk security and alarms etc,i dont lock mine if i take it places most the time.Maye one day that will haunt me tho

Look at it this way, if you lock it they will just cut youre softtop and get in anyway.
Its like some places in the outback, you leave youre fuel flap open, cos if you dont the 'locals' break it open anyway and steal youre petrol.

that would be the case if it was a softtop

just build it and put a small roof basket on thats all ive ever done evan on me old lanndy i had ind charters ville

tru that, i want a roof basket they rock!!!

Well first to comment on the COG vs body lift. Given that the body lift doesn’t give you much clearance advantage I don’t see why you wouldn’t get rid of it. I think you would be a lot happier to be sitting two inches lower on a decent side hill.

The transfer case should still fit, assuming it has been lifted level with the chassis. I have seen this done before, but a cut in the tunnel was required to clear the custom Tcase ring. It should only be a matter of some massaging in the right places though.

The engine I’m not really sure about, have a look in the GTI thread to get some idea’s about clearance.

Virtual lift is the best kind of lift.

As for bike security.. I prefer to never leave the bmx anywhere, but why don’t you lock the bike to the cage. Makes sense

only pics i have of the one i made, cost like 80 bucks. i have about 100 or more of gear on it when we camp.





Adam