DIY roll cage

[JFmb]

I am building a low cost rally car....i wanna do a rool cage myself and weld it

I was wondering what you guys use ( steel, gage ) and what would be the important point to reinforce.

Any pics or your cages or plans and mesurements would be greatly apreciated..

Thanks

[jrally]

If you ever wanted to compete, you would have to follow the sanctioning body rules for your area. If I had to guess, that would be CARS (http://www.carsrally.ca/CARSRally/) In the US it's NASA (http://www.nasarallysport.com/) and RallyAmerica (http://www.rally-america.com/index.php). Otherwise, most people in the US at least use 1-1/2 and 1-3/4" DOM tubing .095 to .120 thickness. If you want simple roll-over protection a basic four point cage with at least one diagonal brace would be a good start.

-Jon R.

[Tuomas]

I did a roll cage for my 4wd project.Here's some low quality pics.

Tubes:

Size is 38*4mm
Reinforcement:

Painted parts:

I did a cage to the roof and weld the other bars to it.



I think you should reinforce those spotwelds on the struttop

[5l1mm]

id recommend paying a pro to weld it, if your not confident that you can weld good.

i mean, you could rock with a welder, but if you dont, it means disqualification, or that death thing.

[MD323]

yeah no cage is better than a poorly done cage.... just more metal for them to have to cut you out of

[MD323]

I did a roll cage for my 4wd project.Here's some low quality pics.

looks good. any reason you didn't add a harness bar?

[FE3-323]

i need to learn how to weld so i can build a rollcage for myself

[jrally]

I've done about 5 so far and helped on a few more. One of my cages even got roll tested!!! If you're truly worried about safety, then yes, have someone who knows what they are doing install it. They can be deadly if done wrong/poorly and like it was said earlier, it would be safer to not have one at all. One you put a piece of cage tubing near you head, and don't wear a helmet, it'll hurt you that much more in an accident. I may have posted a picture of my car parked at my office, but I only live three turns away and I only drive the car about once every other month or so to work.

-Jon R.

[FE3-323]

i don't understand how it could be more dangerous besides impacting your body on it.

[jay]

A badly done cage can either be too rigid and kill you with transient G that otherwise woulda crumpled the car, or better yet kill you by coming apart and impaling you. I'd leave it to a pro, meself....

[Tuomas]

looks good. any reason you didn't add a harness bar?

The cage is not complete in these pictures.I tried to keep it as simple as possible.I've done it so that it won't be in a way when going in or out and the backseat is in it's place.
You should put at least 4mm thick plates over rear wheels arches (if you're gonna weld any bars there).I think they are the weakest places in there.Just buy different shapes etc. > 4mm thick steel.
I wouldn't be afraid of diy cage if you're not a pro welder.Building as supportive as possible and welding with at least 1mm vent between bars to make a good connection.Use seamless bars and reinforce every place where you're gonna weld.Don't use bolt connections.

[FE3-323]

why not weld that rear diagonal bar to the strut tower?

[Tuomas]

why not weld that rear diagonal bar to the strut tower?

I've done it but it doesn't show in these pictures.I'll post some pictures later.