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Not that I would want to cut in on anybody's business, since that is their way to make a living, I would be more than happy to answer any questions you have. I've built cages before, as well as weightlifting equipment (squat racks, bench presses, leg presses, etc.), bag stands, etc.
If I knew how to post pics on sherdog I would write up a tutorial. I can supply you with parts lists, dimensions, etc. as well as give you an idea of where to obtain anything that might be hard to find.
But, the Cliff's Notes version is-
You want 1 1/2" schedule 40 metal pipe (that gives you 1 5/8" OD) for the panel frames. You want to build the frames in 10'-0" sections for a cage that will be 24'-0". Pipe comes in 21'-0" lengths. 1 stick will be needed for each panel top / bottom rail. 1 stick will make 3 uprights (1 1/2 panels). If you make 5 panels (length of chain link roll) this would mean 9 sticks (15'-0" waste) or 8 sticks + a 6'-0" piece.
You need to get thermally fused bonded PVC chain link fencing. Do not get the dipped PVC, it will come off after short usage. The shortest rolls are 50'-0", enough for 5 panels. If you want a full octogan you'll need 8 panels. If you get a 100'-0" roll you'll have 2 extra panels to sell to recoup some of your $$. Or build a 5/8 cage out of the 50'-0" roll. Attach the chain link to the panels with hose clamps @ 16" on center.
Use 1 5/8" closed cell foam pipe insulation (Lowes / Home Depot / plumbing supply house / Grainger / etc.) for 1/2" of padding. If more padding is desired get 2 5/8" pipe insulation to go over the 1 5/8" for a total of 1" padding. The pro panels you can buy use 3/4" padding. 3/4" padding is available (Grainger / plumbing supply house / etc) but costs more than doubling up the 1 5/8" + 2 5/8". In my experiance 1/2" of padding is adequate, you can always add the other 1/2" if you decide it is needed.
The corner poles can be either 3" x 3" square tubing (I use 1/4" wall thickness because I overbuild everything, but pro stuff uses wimpy 11 guage- and brags about it being "heavy duty") or 3" schedule 40 pipe. your panels will be 6'-3 1/4" + / - ( 6'-0" +/- for the fence + 1 5/8" x 2 for the schedule 40 pipe ~always measure your fencing before building since it varies slightly) and you will need them to be up off the floor the thickness of your mats (1.6" for mine) + the thickness of your padding (1" for mine). My corner poles were 6'-5 3/8" from floor to top of cage panel. You want a little play so I made them 6'-6". Square tube comes in 20'-0" length & pipe comes in 21'-0" lengths. Either way you get 3 poles from each stick. If you build a 5/8 cage (1 roll of fencing) you'll need 6 poles, 8 for a full cage. You'll need 8" x 8" x 1/4" plate for mounting brackets on the bottom & on the bottom of the braces. I just bought a 20'-0" stick of it & cut what I needed. The poles get braces on them, I don't remember exact dimensions off the top of my head but they are roughly 3'-6" long & have a 70* angle on 1 end & a 20* on the other (I can check when I get home). If you use pipe you'll have to cope it out. You'll need some "C" channel to mount the panels to the poles, I used a 2" x 2" scrap that I had laying around, cut them 3" long & weld on @ appropriate points (again, coping as needed if using pipe). Square tubing eleminates the need for coping. Each corner is 45* so if using square tubing you can either butt one panel into it and compound the other to get your 45* (the square tube will be 90*) or you can compound both sides to get a 22.5* (22.5* x 2 = 45*).
For doors in the panels you will need an additional 6'-0" pipe for the jamb & another 18'-0" for the frame of the door. And of course hinges / latches.
Prime and paint everything with a good oil based epoxy paint for years of service.
If you really want to get fancy I have panels that can pivot so that they are straight to maximize mat space but you can pull 2 pins & swing it to another pole so that it forms a 45* just like an octogan. And I have a panel design that can be adjusted by turning bolts to tension the chain link so that it is consitent as it stretches. More work & material in those designs though, probably not for a 1st timer trying to build a cage.
If you have any questions feel free to ask. I also have pics of the complete construction sequence from raw material to installed panels, if I could figure out how to post them (and found the time).
Last edited by laohu69; 10-07-2011 at 11:14 AM.
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