Diy Roll Bar

[Denz]

This isnt a walk through and will be quite picture heavy its just a list of events that ended up with me having a new almost finished roll bar.
First full link to album,
http://s563.photobucket.com/albums/ss80 ... MX5%20Fun/
sorry I couldnt borrow a real camera these are all just phone camera pictures
Id like to say first off thank you a lot to Chase, he is a wizard and a good mate. Standing around like a useless prick watching him was a pleasure and im still amazed that ANYTHING can be done with what he and his dad have laying around.

Got there Monday and had time so went to the beach


Finally got to it and stripped it down to figure out where we were going to put things.

This is the underside of the car after we removed a panel which is where the bolts now go through for the rear plates for the rear bars (not done yet)







Some rough measurements


Some plates for the side


and a rough guide of what the end result will be

The plates on the side go through two already existing holes and a third will be drilled and bolted in when the rear arms go on. Unfortunately I had to leave a bit earlier than desired so made the call to leave it for the moment.

Day two, serious business

(had to start late and waste some time to miss Auckland traffic)

Important machine one

Important machine two

Important machine three


Stuff up one


Found one of these which became a very useful tool


Second times the charm



(sorry it was a bit hands on bending these no action shots)



Fit was pretty darn good
In preparation for the rear arms we found a holesaw


Yup that works


We got the bar perfect and got welding

Once it was all tact in place

Action shot!

The welds are not "perfect" but its 42mm dia, 3mm sidewall steel and it was the first time he had used CO2 rather than argon, I couldnt even break the tacts off so im pretty sure of the strength.
Bolting it in place

A pretty happy me!


Other things I got done on the car
I know we can gut the cat!

Looks like someone got to that before us.
I know straight pipe with what ever is laying around.

And lets move that number plate again using things we found on the floor



Bonus round

Ass shot, boom



I think its an LSD, wheels move with each other etc

300hp Prelude with the engine now in the boot


The tractor that ran the hydraulic ram of the pipe bender

Just a couple of dirt track race cars, that RX7 has a V8 in it


Side note photobucket is a PITA

More than happy to answer any questions, I really need to be in bed right now or else this would look a bit better.

[dynofiend]

Looks great, well done on taking the DIY route. However a word of caution:

Even though the bar is behind the drivers head, there is still a very good chance that in a serious enough accident (especially a rollover, and especially as you still have 3 point belts) that the driver or passengers heads could connect with the bar. If you're in 'road mode' at the time with no helmets, that is pretty serious. Any bar that is vaguely near to the head should ideally be protected with the nice dense FIA style foam padding (not pipe lagging!) which is not really very expensive.

If I was being super picky, id also have a little frown at the squared off pointy corner facing the back of the drivers head too. Much better if that could be flattened off like the back side of the same flange.

[Denz]

Yeah once its done I will be padding it although I would have to be right out of the seat to possibly hit it.
The bits of steal will be hidden by the trim once I modify it
I appreciate any feed back

[Snapfrozen]

First concern would be safety, then looks. I would almost be tempted to have an LVV certer look at it, or at least a MSNZ scrutineer. Had my civic looked at multiple times and the scrutineer was happy when I brought it to him, purely that I was worried about safety over other factors