Roll Cage Project

In November of 2009 I decided I could not continue with the FIAT's roll bar. So I launched into my own roll cage project. I had checked with several sources on having a cage made, but they were all upwards of $3000.

So ordered some tube, got a bender and cutter from a friend and off the races we go.

Build Blog

Total of 810" of tube used. (108' or 1296")

15 Feb 2010 She's done. I'll sort out the left over bars, but it looks like 28-30' left 360", but that does not jive, but could be true. 10' of waste.

14 Feb 2010 Jeff and I over a span of 20 hours tig'd and mig'd the cage back into the car.

06 Feb 2010 Overhead 57", Front Wheel Wells x2 10", Forward 1" Gussets x2 7.5", Main Loop Gussets x2 10", Pass Door Bars x3 8".

26 Jan 2010 Passenger side bars. x2 40" (upper and lower) + 60" harness bar

17 Jan 2010 Drive side door bars. x2 48" (upper and lower bends) + 39" straight.

11 Jan 2010 Used 48" for the lower front member and 47" for the upper front member.

02 Jan 2010 Bent the 2 A pillar sections today. 80" with a 25 degree bend and 65 degree bend.

30 Dec 2009 Managed to get the main loop chopped down and leveled. 3" of head clearance.

16 Dec 2009 120" section for the main loop. Got the math correct and managed to bend the main loop successfully.

12 Dec 2009 24" section lost to bad bends. We tried to make the main loop, but it ended up too wide. So lost some material. We measured up and got the math figured out.

RACE ROLL CAGE SPECS

108' 1.5" x 0.095" DOM round steel tube
3/16" 4" x5" plates
2' 1" DOM round steel tube

Costs $1360.08

$67.75 Mig gas refill (29 Sept 2009). Air Liquide Canada.
$63.22 Mig wire and tips (09 Oct 2009). Princess Auto.
$101.69 Mastercraft Cut-off Saw, 14-in (21 Nov 2009). Canadian Tire.
-$101.69 Saw was damaged. Refunded due to lack of replacement parts. Fixed it myself.
$545.11 108' 1.5" x 0.095" DOM Tube (25 Nov 2009). Metal Supermarkets.
$84.00 Pipes, plates and square tubes cage & cell (28 Nov 2009). Metal Supermarkets.
$600 Tig/Mig welding (13/14 Feb 2010). Photos.

Tools

Mig welder, bender, cutter, saw & so on.

Photos

25 Nov 09 Tubes	09 Dec 09 Grinding
12 Dec 09 Bending	16 Dec 09 New Main Loop
26 Dec 09 Grinding	28 Dec 09 Plates
30 Dec 09 Tacked	02 Jan 10 A Pillars
07 Jan 2010 A Pillar	11 Jan 2010 Driver A Pillar
14 Jan 2010 Tacking	17 Jan 2010 Driver Door Bar
21 Jan 2010 Door Bars	26 Jan 2010 Harness Bar
14 Feb 2010 Cage Tig