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 25 From Rollbar to Rally Cage (Read 11842 times)
Noah
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From Rollbar to Rally Cage
May 28th, 2017 at 12:36am
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Figure I'd document changes that are happening to "Wilson".

DIY roll cage building. I'm totally green. Never built a cage, never used a bender.
Using DOM 1.75" x .120" locally sourced tubes.
Will be bending & cutting using "affordable bender" purchased with 1.75" die.

Presently Wilson has a Hanksville rollbar, but I want to make it a FIA style rally cage.

This is my bender: 1-3/4" Tube Bender Pipe Bender by Affordable Bender

Using this incredible video as my notching guide.
https://www.youtube.com/watch?v=mHBanmfn_CA&t=80s

and finally...

FIA rules (if you can find what you are looking for, LOL.: http://www.safetydevices.com/uploads/ckfinder/appendix_k_-_technical_regulations...
  

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Noah
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Re: From Rollbar to Rally Cage
Reply #1 - May 28th, 2017 at 12:13pm
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I have decided to try and mimic the 944 cage from www.cagethis.com. I really like their product & their product is affordable. I was going to buy their kit but I've already welded in my Hanksville rollbar.

Plus I'd like the experience. Here are pics I'm referencing from CageThis.com. This is FIA rally compatible. Though I'm unsure if the "tacos" are a requirement as some joints.

Notice how the a pillar tubes don't go int the vents. I require full HVAC function in my late model car.... a/c and heat just like Porsche intended. Yes it'll make ingress/egress harder but there are a couple of things I am thinking of the deal with that.







  

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Noah
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Re: From Rollbar to Rally Cage
Reply #2 - May 28th, 2017 at 12:23pm
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BTW- here are my "shop notes" based on the Fabrications Series Youtube video. Easy to print off if you are lazy, but it only makes sense if you follow the videos instructions.
I actually got a Eastwood tube notcher & hell if I can figure it out. I think I'm missing something... it just ***es me off and then I put it back on the shelf everytime I go to use it.

These instructions empower me. Thank you Fabrication Series! I love your material & presentation.
pg1

pg2

  

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Noah
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Re: From Rollbar to Rally Cage
Reply #3 - May 28th, 2017 at 12:38pm
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My most favourite door bars for easy in/out appear on the WTA RP968. Can't seem to find great pics, but here's a couple to give you the idea. I will be using "U" door bars not "X". This car is a daily driver for me. When it's not in the shop.


  

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Noah
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Re: From Rollbar to Rally Cage
Reply #4 - May 28th, 2017 at 12:48pm
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Noah
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Re: From Rollbar to Rally Cage
Reply #5 - May 28th, 2017 at 2:44pm
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This morning must start with getting rid of sh!t I don't need then a bit of cleanup. I can't work under these conditions. Management at Wilson Racing headquarters has been too slack with the technicians.



  

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Re: From Rollbar to Rally Cage
Reply #6 - May 28th, 2017 at 10:27pm
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Wow! The last picture looks like a spare car just waiting to happen...
  
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Noah
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Re: From Rollbar to Rally Cage
Reply #7 - May 31st, 2017 at 5:53am
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haha... yeah, no doubt! I unloaded them on my buddy who has 3 944s.

-----

Hood pins mounted using lightweight cromoly bicycle tubing. The crossmembers are made from high grade bicycle forks.


  

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Noah
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Re: From Rollbar to Rally Cage
Reply #8 - Jun 3rd, 2017 at 2:44pm
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Found this Chart of strength/weight/price. Don't know the accuracy. I do know I came home with 3 times 8 foot sections of 1.75"x.095" DOM yesterday. Just for kicks, picked up the 1.20" thick tube for comparison. It feels to me that 24 feet of 1.20 is about 7-15 lbs heavier, so a full cage would weight about 35-45 lbs heavier then the .095".

Tube Costs per Tube Service      
Based on 20 foot length purchases.      

Chrome-Moly       Tensile Stength =      90,000      psi      
Diameter (in)      Thickness (in)      ID (in)      Cross Sect. Area (in^2)      Tensile Strength (lbs)      Cost ($/ft)      Weight (lb/ft)
1.75      0.120      1.51      0.61      55,303      $6.63      2.089 lb
1.75      0.095      1.56      0.49      44,453      $6.59      1.679 lb
1.75      0.083      1.58      0.43      39,119      $8.17      1.478 lb
1.50      0.120      1.26      0.52      46,821      $6.01      1.769 lb
1.50      0.095      1.31      0.42      37,738      $5.74      1.426 lb
1.50      0.083      1.33      0.37      33,253      $5.51      1.256 lb
1.25      0.120      1.01      0.43      38,339      $5.65      1.448 lb
1.25      0.095      1.06      0.34      31,023      $5.44      1.172 lb
1.25      0.083      1.08      0.30      27,386      $5.50      1.034 lb
1.00      0.120      0.76      0.33      29,857      $5.54      1.128 lb
1.00      0.095      0.81      0.27      24,308      $5.42      .9182 lb
1.00      0.083      0.83      0.24      21,519      $5.39      .8129 lb
1.00      0.065      0.87      0.19      17,183      $4.98      .6491 lb

DOM       Tensile Stength =      70,000      psi      
Diameter (in)      Thickness (in)      ID (in)      Cross Sect. Area (in^2)      Tensile Strength (lbs)      Cost ($/ft)      Weight (lb/ft)
1.75      0.125      1.50      0.64      44,668      $5.54      2.169 lb
1.75      0.095      1.56      0.49      34,575      $5.36      1.596 lb
1.75      0.083      1.58      0.43      30,426      $5.23      1.478 lb
1.50      0.120      1.26      0.52      36,416      $5.18      1.769 lb
1.50      0.095      1.31      0.42      29,352      $5.92      1.426 lb
1.50      0.083      1.33      0.37      25,863      $5.61      1.256 lb
1.25      0.120      1.01      0.43      29,819      $5.28      1.448 lb
1.25      0.095      1.06      0.34      24,129      $5.00      1.172 lb
1.25      0.083      1.08      0.30      21,300      $5.57      1.034 lb
1.00      0.120      0.76      0.33      23,222      $5.00      1.128 lb
1.00      0.095      0.81      0.27      18,906      $5.00      .9182 lb
1.00      0.083      0.83      0.24      16,737      $5.00      .8129 lb
1.00      0.065      0.87      0.19      13,365      $5.00      .6490 lb
  

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Noah
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Re: From Rollbar to Rally Cage
Reply #9 - Jun 3rd, 2017 at 5:43pm
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Step 1 complete in 1.5 hrs this morn: organize garage, empty car. Took a few pics to show how nasty my car is from amateur rally type events and playful gravel driving. I hope to have a nice car by  the time I'm done.



  

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Noah
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Re: From Rollbar to Rally Cage
Reply #10 - Jun 3rd, 2017 at 9:36pm
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First bend turned out beautiful. I am giving myself extra length to get a sense of how it bends. First bend goal was 22.3 degrees and accomplished 23.5 degrees. Now the tricky part will be keeping the follow up bends aligned properly.

I'm using a digital caliper and angle finder to mark the tube & I've marked the bender so the alignment should be sound.


  

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Noah
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Re: From Rollbar to Rally Cage
Reply #11 - Jun 3rd, 2017 at 11:31pm
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Wow if you are careful you can have bends within 1 degree or better with this method.

...but somehow I over bent 10 degrees. Need to wrap my pea brain around that before I continue... figure out how I made the error, so I don't make a habit of it. So far I'm very impressed with the tools for the price I paid.



  

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Noah
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Re: From Rollbar to Rally Cage
Reply #12 - Jun 4th, 2017 at 6:22am
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Realized the errors of my ways, simply was measuring the wrong thing for the second  bend. Looked up FIA specs & you aren't allowed to bend a second bend on the lower tube, but there isn't a rule stating a limit on bend on the top tubes... meaning I can put a "corrective (reverse) bend in the upper portion of the A pillar tube. That should do nicely. I was confident enough to bend the second tube to match, though it appears I need to bend it a bit more, so it *actually* matches. hahaha. No big deal.



All was fine and dandy until my bud roles up with a super rare dream car... and that basically used up the rest of the night.  Wow. 502 whp r32 n1 factory clubsport type car. 1 of 4 in Canada. Amazing....



  

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Noah
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Re: From Rollbar to Rally Cage
Reply #13 - Jun 4th, 2017 at 11:20pm
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Learned an expensive lesson: If you over bend a tube, there is no saving it.
  

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Re: From Rollbar to Rally Cage
Reply #14 - Jun 5th, 2017 at 12:06am
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Don't be discouraged - nothing is ever "wasted"...
It is part of the learning curve for your new skill.
Surely you will need some small sections of tubing for bracing or triangulating along the way and you can cut them off the incorrectly bent piece.
At least practice the art of coping the end sections for welding on that.
Worst case - make some kind of Mad Max bumper out of it! Cheesy
  
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