Build Spotlight: RZR Turbo S Full Cage, Bumpers, and Doors

This 2023 RZR Turbo S rolled into the shop back in January. The owner — Jake out of Harrisonville — had been riding it stock for about six months and decided he was done replacing plastic body panels every other weekend. His exact words: "I'm tired of zip-tying my fenders back on."

Fair enough.

The Plan

Jake wanted a full cage, front and rear bumpers, half doors, and a roof. No wild paint job, no RGB light bars, no "influencer build" nonsense. Just solid protection that'll hold up on Missouri trails and the occasional trip to Windrock.

Here's what we specced out:

• Cage: 1.75" x .120 DOM main hoop, 1.5" x .095 DOM supports, gussets at every node
• Front bumper: 3/16" plate with integrated winch mount and four light tabs
• Rear bumper: 3/16" plate with tow points and mud flap mounts
• Doors: Tube-frame half doors with aluminum skin panels
• Roof: .090 aluminum sheet with integrated rain gutters

Build Notes

The Turbo S is one of the wider RZRs Polaris makes — 72 inches. That extra width means the cage needs longer crossbars and the roof panel is bigger, which means it flexes more if you don't design it right. We added a center support rib to the roof and ran the rain gutters as structural channels instead of just cosmetic bends. Keeps water out and keeps the panel stiff.

For the bumpers, we went with 3/16" plate instead of the 1/4" we'd normally use on a slower machine. The Turbo S weighs a lot. Every pound counts on a machine that already tips the scales at 1,900+ lbs dry. The 3/16" plate handles impacts fine for trail riding — we'd go heavier for a dedicated desert race truck, but this isn't that.

The doors took the most time. Tube-frame doors look simple until you realize every one has to open, close, latch, and clear the cage tubes without binding. We hung these doors four times before we were happy with the gap and the latch engagement. That's normal. Doors are annoying. But they're worth it when you're plowing through a mud hole and your passenger stays dry-ish.

Turnaround and Cost

Total build time was about three weeks. We quoted Jake at $3,800 for the package and came in right at that number. No surprise charges, no "well the metal prices went up" excuses. We quoted it, we built it, done.

Jake's been running it hard since February and sent us a photo from Windrock last week. Cage has some scrapes on it — which means it's doing its job.

Want to see what we can do for your machine? Send us your build idea and we'll put together a quote.