Mountain Off Road WCK150 - Manual (Page 2)

M.O.R.E.™ recommends pre-fitting this Sport Cage into your Jeep® BEFORE you paint it, before you drill any holes
in it or your Jeep®, and before you weld any thing!!! Make sure that you can make it fit and that you are happy with
all aspects of it. If you are, then proceed with these instructions. After installing it, remove it to prep and paint it, then,
re-install it. Remember, Once you modify it in any way, it is NON-RETURNABLE !!!
STEP 1.
Park the Jeep® on a flat, level surface. Remove the top.
STEP 2.
UN-zip the roll par padding cover. Note: On weathered zippers it is a great idea to lubricate the zip-
pers with silicone spray to ease their operation.
STEP 3.
Remove padding from the main hoop of the factory roll bar.
STEP 4.
Remove carpet, seats (and brackets from floor), and any other items that may be damaged from
grinding and welding.
STEP 5.
Insert the connectors into the L&R side bars, with the taper angle out, and matching the angle of the
factory roll bar. SEE FIGURE 1. Install the L&R side bars into the Jeep®. Install the cross-bar onto the pre-welded
stubs and use a ratchet strap, rope or other device to pull the side bars together and hold the cross-bar in place.
SEE FIGURE 2.
STEP 6.
With your helper holding the Sport Cage in place, use a level on the horizontal part of the L&R side
bars and level them (0°). SEE FIGURE 3. Mark the factory roll bar where the connectors contact it (with a ink-type
marker). SEE FIGURE 4. Remove the Sport Cage. Grind/sand the paint from the area marked. SEE FIGURE 5. Re-
install the Sport Cage. Re-level it. Check to make sure that it clears all or your interior components. TACK weld the
connector stubs to the factory roll bar in several places. SEE FIGURE 6. DO NOT weld the side bars to the connec-
tors!
STEP 7.
The L&R side bars will “slide” in and out of the connectors slightly, for front and back adjustment.
Place the Sport Cage where you want it in the Jeep®. Place the L&R bars (side to side) where they will allow the
doors to close without contacting them, and for padded dash clearance. SEE FIGURE 7. Once you are sure that you
have the side bars placed where you want them, check under the Jeep® to make sure that you will not drill into any
other components. Using the pre-punched floor plates as a guide, drill holes in the sheet metal floor to 3/8” with a
power drill. SEE FIGURE 8. Use the bolts provided, 3/8” x 1-1/4”, USS (large) flat washers and crimp-loc nuts, and
snug tighten only.
STEP 9.
Install the cross-bar over the L&R side bars. With the ratchet strap still holding tension on the as-
sembly, drill the cross-bar with a 3/8” bit and drill through the pre welded stubs. SEE FIGURE 9. Bolt the cross-bar
to the stubs with the 3/8” x 2-1/4” bolts, SAE (small) flat washers and crimp-loc nuts.
STEP 10.
You can now drill the side bar connectors with a 3/8” bit. Use the pre-drilled holes in the L&R side
bars as a guide. You may want to pre-drill the connectors with a 1/8” bit as a pilot hole to aid the 3/8” bit. SEE FIG-
URE 10. Remove the Sport Cage by sliding it forward off of the connectors. Be careful not to break the tack welds
on the connectors loose from the factory roll bar.
STEP 11.
Weld the connectors to the factory roll bar. Let them cool naturally, without quenching. Wire brush
the weld area and paint the connectors and surrounding area to match your factory roll bar. Re-install the factory roll
bar padding and cut a small circle around the connector area to allow it to pass through the padding. SEE FIGURE
11.
STEP 12.
With the Sport Cage out of the Jeep®, prep and paint it. While the paint is drying, vacuum out the
floor board of the Jeep®. Re-install the Sport Cage in the Jeep®. Bolt the L&R side bars to the connectors with the
3/8” x 2-1/4” bolts, SAE (small) flat washers and crimp-loc nuts. SEE FIGURE 12. Bolt the floor plates to the floor.
Re-install all components removed earlier and cut the carpet around the cage tubes.
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