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OK, I am back after a bit of a delay. Had to go to Brazil for a couple of weeks on business, had a family surgery / health scare (OK now), etc.
An update on this - I am making better progress than I expected on the hard top and so am going to scratch the soft top for now. So I will likely just do the full external cage as close to the safari top as possible, since the consensus seemed to be that that top would be taller than the soft one, so the cage should work with either.
Since at some point the truck will hopefully be used for longer trips, the roof rack will be mounted to the top of the cage. The trailer idea is a good one but it is going to double the cost if I am going to do a cage anyway. A roof rack would be much cheaper, plus I could have an awning off the external cage. Pic of belt and suspenders on a Jeep:
http://expeditionportal.com/mscott/U...yonesema22.jpg
I found this pic which gives an idea of the kind of mounts that could be attached to the capping and come out underneath the canvas (these come straight out; they could be angled down and curved to come out under it):
http://cdn2.overlandsphere.com/wp-co...023-flickr.jpg
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For my own reference as much as anything, here is an example of one that is kind of a hybrid approach to putting a roof rack on top of a soft top. The hoops may be beefier than the standard ones and so maybe would work better for the roof rack, but since they are not tied to the frame it probably wouldn't help all that much in the event of a roll over. (which didn't seem to be the owner's objective so I am not criticizing.)
Another concern is that puncturing the canvas top to get the bolts through would likely result in leaks in the future or weak spots from which tears would develop...
http://www.landroveraddict.com/forum...threadID=29069
http://www.mark-90.pwp.blueyonder.co.uk/alf/cage.jpg
http://www.mark-90.pwp.blueyonder.co.../cagefront.jpg
http://www.mark-90.pwp.blueyonder.co...f/cagerear.jpg
http://www.mark-90.pwp.blueyonder.co...f/cageside.jpg
http://www.mark-90.pwp.blueyonder.co...cageinside.jpg
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One more of that truck with the sides down:
http://img.photobucket.com/albums/v1.../alfrocks1.jpg
That is nice work.
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Also for reference, this site has pics of the same cage on both soft and hard tops. It appears that it might not fit with a safari top with the sunsheet as it is awfully close to the hard top that doesn't have one on it.
http://www.whitbread-offroad.co.uk/r...l_external.php
http://www.whitbread-offroad.co.uk/r...external_6.jpg
http://www.whitbread-offroad.co.uk/r...external_7.jpg
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Enjoying this brain storming thread. Based on what you want to build you are going to have some technical bends, design work and a good welder. So since you are going to need all that anyway what about doing a "surface" mount roof rack like you want but rather then go down to the frame on all 6 points like the Safety Devices diagram (page 2) just go to the frame on the main hoop behind your head. In the event of a bad roll over the 4 points on the cage not attached to the frame would be trashed but the hoop behind your head would hold and keep the truck from crushing you. When I mean "surface mount" I mean run the tubes down the side just like the safety devices cage shows. Except for the two for the hoop behind your head are finished to the frame. But then again if you made it that far why not just run internal tubes down to the frame on the other 4 points and make a copy of the safety devices cage except a little taller so you can do your top swap. After reading this I'm rambling but I'll post it since it's typed.
One more thing, I agree bolting through the canvas top would cause ripping down the road.
pb
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Thanks PB, appreciate the thoughts.
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Any updates on progress? I am also considering something similar on my SIIA for carrying surf boards and kayaks.