Protecting Outrigger Cylinders with Custom Guards

[MikePhua]

Why Outrigger Guards Matter
Outrigger cylinders on backhoes and loader tractors are vulnerable to impact damage, especially during brush clearing, log piling, or demolition work. These polished hydraulic rods extend below the machine’s frame and are often exposed to falling debris, rolling logs, or accidental contact with stumps and rocks. A single dent or scratch can compromise the seal, leading to hydraulic leaks and costly downtime.
Machines like the Case 580M and Caterpillar 420DIT are frequently used in rugged environments where such damage is common. While some models come with factory-installed guards, many rely solely on hose protection or offer limited shielding for the cylinder rod itself.
Factory vs Aftermarket vs DIY Solutions
Factory guards are typically available through OEM channels, but prices can be steep and availability limited. For example, Case may only offer certain guards as part of a full assembly, making replacement expensive. Caterpillar’s used parts division sometimes stocks individual guards, but compatibility must be verified by serial number and model variant.
Many operators turn to aftermarket suppliers or fabrication shops to build custom guards. These solutions offer flexibility in design and can be tailored to specific working conditions. A popular DIY approach involves:

• Using 6" or 8" Schedule 40 pipe, split lengthwise to form a half-shell
  
• Welding flat bar tabs for mounting at the pivot end
  
• Adding a rubber block or floating end to ride against the cylinder without binding
  
• Painting and stamping for corrosion resistance and identification
  

This method has been successfully used by field mechanics and small contractors. One operator in Oklahoma fabricated guards for his John Deere 310 using scrap pipe and a hydraulic press, saving over $600 compared to OEM parts.
Design Considerations and Material Selection
When building or selecting outrigger guards, consider:

• Material strength: Use mild steel or reinforced aluminum for impact resistance
  
• Mounting method: Ensure guards do not interfere with cylinder travel or restrict movement
  
• Drainage and debris clearance: Include slots or holes to prevent mud buildup
  
• Ease of removal: Guards should be serviceable without dismantling the entire outrigger
  

For high-impact environments, thicker wall pipe and gusseted mounts are recommended. In forestry applications, guards may need to withstand repeated log strikes and resist bending.
Opportunities for Small Fabricators
The demand for outrigger guards presents a niche opportunity for local metal shops. By offering custom-fit guards for popular models like the Case 580, Cat 420, and Deere 310, fabricators can serve contractors who need fast, affordable protection. With basic tools—a brake press, welder, and pipe cutter—shops can produce guards in batches and sell them regionally.
In Oregon, a small fabrication business began producing outrigger guards after a local contractor requested replacements for a damaged set. Within a year, the shop had expanded to offer guards for five different models and began shipping nationwide.
Recommendations for Operators

• Inspect outrigger cylinders weekly for signs of impact or scoring
  
• Install guards before brush or demolition work
  
• Use rubber dampers to reduce vibration and wear
  
• Document guard dimensions for future replacements or upgrades
  
• Share designs with local shops to streamline fabrication
  

Conclusion
Outrigger guards are essential for protecting hydraulic cylinders in harsh working conditions. Whether sourced from OEMs, built in-house, or fabricated locally, these guards prevent costly damage and extend machine life. With creativity and practical design, even small operators can equip their machines with robust protection tailored to their environment.