Good stuff there, guys. I had been mentally running through the option of the Halo bar as opposed to the 1 piece A pillar / roof bars. I can see how the halo bar would be easier to fab and weld. I'm going to give plenty of consideration to that option. This is the first cage I have ever built, so I'm trying to weigh the ease of fabrication into the equation. Obviously, safety is the goal, but I also need to be able to build this thing in practical terms.
I suppose I could attempt the individual A bars first, and if I run into too much problem getting good fitment, I could cut them off at the roof line and "re-do" with a halo bar. My main concern with the individual A bars is getting both sides bent the same, to have good symmetry from side to side. What are the other difficulties with individual A-bar construction?
Also a good suggestion to swap #10 and #8. With respect to a short leg from the rocker to the subframe rail - I have a boxed in section at the front location, which runs under the floor from the rocker channel to the subframe rail. Since this truck had plenty of rust, I have replaced the factory subframe rail with a length of 2-1/2" x 3/16" walled square tubing. The boxed in section from the rocker to the subrame rail is 1/8" sheet, and will have 1/8" sheet at the floor as well, with 1/4" plate on top of the 1/8" sheet at the cage mounting point.
At the rear of the cage, however, there is no subframe rail, just formed sheet metal. I am building a 1/8" thick system of support on the inside of the cab, tying together the inside rocker channel with the rear corner of the cab. The 1/4" thick cage mounting pad will sit on top of this structure.
Steve.