Forklift safety cage

[Paul Allwood]

Today I made a start on modifying an old steel stillage I bought for $50 to turn it into a forklift safety cage.

Here's what I'm starting with.





The first job was to get the uprights square to the base. It's hard to see in the pics but they were pushed inwards by about 2" at the top. For this I used some chain and a cab lifter that I made to raise the cab on our Unimog. It was slow to get set up but it worked.

17 September 2026

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It's not perfect but close enough for me.



I made brackets to locate the fork tines so I can lift it from either the long or short side and welded them to the underside of the base.





Next up, some chains or bars for the open sides to stop me falling out.

I'm open to suggestions for what else might be useful if you've used one of these.

 

[Runs With Scissors]

Just off the top of my head, I would think some sort of "D rings" in order to attach a "safety rope" or some sort of "safety/limiting harness" ?

 

[Paul Allwood]

Just off the top of my head, I would think some sort of "D rings" in order to attach a "safety rope" or some sort of "safety/limiting harness" ?

You mean like a safety device on a safety device (cage) ?

 

[ruger1980]

One thing you might consider is something to roughen up the floor to help during slippery conditions like expanded steel or grates of some sort. Possibly rubber mats could help with slipping and fatigue.

 

[Bee-Positive]

You mean like a safety device on a safety device (cage) ?

Yes - we don't want to loose you because you were reaching that last 2" because you didn't want to get down and move the cage over.

 

[ken erickson]

While I never used one I would think a built in tool/small parts tray attached along one of the top rails would be a handy addition.

 

[Russell King]

I would add some adjustable length long legs to the four corners since hydraulics can fail. I guess you could add some lock to the lift cylinders for that instead of legs.

 

[Caden]

since hydraulics can fail

I agree on adding legs or stands.

It's one thing to go up on a real forklift, but even worse when you have a tractor that can dump you, roll over, or, unlike a forklift, drop suddenly if a line fails.

Extra safety here can't hurt.

 

[NCL4701]

There’s a fair bit of hand wringing online about using personnel cages on loaders. Using any sort of lift, particularly off road, the strengths and weaknesses of the system should be soberly considered and risk assessed to determine if it’s within the risk tolerance of those involved.

Most often the choice isn’t between a personnel cage on a loader or a dedicated personnel lift, it’s a choice between a personnel cage on a loader or a ladder. I’ve spent about 1000x more time on ladders than in personnel lifts on loaders, but I’ll choose the personnel lift on a loader every time there’s a choice between the two. If I had a choice between falling 10’ off a ladder or riding down a loader from 10’ with a failed hydraulic line, I’d still choose the loader. I’d also choose a dedicated personnel lift over a loader if that was an option.

BTW, I’ve had boom cylinder lines fail on loaders twice: once due to lack of maintenance (hoses likely over 40 years old) and once due to defect (less than 100 hours on my L). A hole in a line with a light load (such as a person) doesn’t result in the boom coming down anywhere near the 32 ft/sec squared experienced falling from a ladder. I’ve had my father free fall the boom on a tractor loader from 9’ with me in it due to an alleged problem with the valve that never happened before or since. It was a bit surprising, but otherwise not a big deal. I’ve also had a hydraulic jack fail while I was under a 1/2 ton truck and, due to my laziness, I’d neglected to block the 1” gap between the truck frame and the fully extended 50 ton screw jack I was using for a jack stand. Truck fell 1” near instantly; hit the screw jack like a steam hammer.

Not trying to talk anyone into using a tractor loader for lifting personnel. There are risks with any aerial work (personnel lifts and bucket trucks roll over and hit power lines just as easily as utility tractors). Use a personnel lift or ladder or boom lift or hire out aerial work; whatever matches the job and risk tolerance of those involved.

Loader is still better than a ladder and a personnel basket on a loader is better than standing in a bucket. Just an opinion. YMMV.

 

[Paul Allwood]

There’s a fair bit of hand wringing online about using personnel cages on loaders. Using any sort of lift, particularly off road, the strengths and weaknesses of the system should be soberly considered and risk assessed to determine if it’s within the risk tolerance of those involved.

Most often the choice isn’t between a personnel cage on a loader or a dedicated personnel lift, it’s a choice between a personnel cage on a loader or a ladder. I’ve spent about 1000x more time on ladders than in personnel lifts on loaders, but I’ll choose the personnel lift on a loader every time there’s a choice between the two. If I had a choice between falling 10’ off a ladder or riding down a loader from 10’ with a failed hydraulic line, I’d still choose the loader. I’d also choose a dedicated personnel lift over a loader if that was an option.

BTW, I’ve had boom cylinder lines fail on loaders twice: once due to lack of maintenance (hoses likely over 40 years old) and once due to defect (less than 100 hours on my L). A hole in a line with a light load (such as a person) doesn’t result in the boom coming down anywhere near the 32 ft/sec squared experienced falling from a ladder. I’ve had my father free fall the boom on a tractor loader from 9’ with me in it due to an alleged problem with the valve that never happened before or since. It was a bit surprising, but otherwise not a big deal. I’ve also had a hydraulic jack fail while I was under a 1/2 ton truck and, due to my laziness, I’d neglected to block the 1” gap between the truck frame and the fully extended 50 ton screw jack I was using for a jack stand. Truck fell 1” near instantly; hit the screw jack like a steam hammer.

Not trying to talk anyone into using a tractor loader for lifting personnel. There are risks with any aerial work (personnel lifts and bucket trucks roll over and hit power lines just as easily as utility tractors). Use a personnel lift or ladder or boom lift or hire out aerial work; whatever matches the job and risk tolerance of those involved.

Loader is still better than a ladder and a personnel basket on a loader is better than standing in a bucket. Just an opinion. YMMV.

Thanks for your comments. I agree - I would rather be in a cage on a loader than on a ladder.

Since our tractor is small the maximum height for the platform is only 6 feet, but I'm still planning on sliding steel tube down the corner uprights as legs....just in case.

 

[Runs With Scissors]

You mean like a safety device on a safety device (cage) ?

Yes,

I know it's a bit over kill, but just an idea.

When I worked for Chrysler Aviation we had lifts that went up quite high (maybe 30'ish feet) and we were required to "strap in" when we used it.

For your 6 foot lift, it may not be a great idea though

 

[Paul Allwood]

Yes,

I know it's a bit over kill, but just an idea.

When I worked for Chrysler Aviation we had lifts that went up quite high (maybe 30'ish feet) and we were required to "strap in" when we used it.

For your 6 foot lift, it may not be a great idea though

Yeah, I don't think I'll use a harness. At 6 feet up I think it would be hard to make it effective.

 

[Bee-Positive]

A tale of caution: My son in his early 30's was loading his pickup. Standing on the tailgate he hopped down to the gravel driveway, about a 30" drop (3/4 of a meter). He landed stiff-legged and fractured his knee cap. Now has 3 screws holding it together.

What I'm saying is just be careful no matter what height you're working at - stuff happens.

 

[Runs With Scissors]

Yeah, I don't think I'll use a harness. At 6 feet up I think it would be hard to make it effective.

Maybe you could add a device that catch's you when you bounce back up?