View Full Version : Roll Cage
makeitfit
05-04-2015, 22:27
Can you tell what it is yet ?
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150405_171916_zps3xsdvp21.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150405_171916_zps3xsdvp21.jpg.html)
don simon
05-04-2015, 22:29
Removable roof section for the ejector seat?
Either it's a drawing of how your going to do a rear roll cage for the T2 or a poss rear window blank if you turn the Troll into a pick up/ tray back:nenau
AlexD333
05-04-2015, 22:55
Clueless I'm afraid
makeitfit
05-04-2015, 22:59
Sweety is nearest :rolleyes:
Now what's he going to plump for ?
Sweety is nearest :rolleyes:
Now what's he going to plump for ?
I'll go for drawing & template for the rear cage in the Mav:augie
makeitfit
05-04-2015, 23:15
Bugger, short quiz it is then :lol
don simon
05-04-2015, 23:23
If it isn't a removable roof section for an ejector seat, it bloody well should be.
makeitfit
05-04-2015, 23:25
If it isn't a removable roof section for an ejector seat, it bloody well should be.
It isn't but I'll look into it :)
AlexD333
06-04-2015, 00:08
It isn't but I'll look into it :)
And to think I stayed up to find out too... I'm off to bed!
*pours coffee away* :p
makeitfit
18-04-2015, 20:42
I did a bit more on the roll cage :D
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150418_193635_zpslsrajiaf.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150418_193635_zpslsrajiaf.jpg.html)
I forgot all about this:doh what did I win Pete:nenau:lol interested to see how this comes out:thumbs
makeitfit
20-04-2015, 21:26
Your prize is all my experimenting :D BBC and all that :thumbs
Anyway for your prize winning delight , here's this afternoon's mayhem :thumbs
To cut a long story short I couldn't really get a satisfactory tight bend so went up to the blacksmiths to use his big bender :D
Unfortunately it kind of broke :o
In the process got a nasty kink where we didn't want one. He said he'd get me a new length of tube and sort it out. In the end that one got bent in the wrong place , even with my template :doh
Anyroad up , I came away with a load of tube at half price and some internal sleeving.
I did the waist line bends to suit the shell and got this
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_192344_zpsybe6h0hr.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_192344_zpsybe6h0hr.jpg.html)
Internal diameter of the CDS is 40mm as best I could measure it. Got some 40 mm tube with 6mm wall thickness and tried to makeitfit :augie As you know, a 40mm tube wont fit in a 40mm hole. So after a clean up and a session in the freezer I got this
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_193502_zpsc7uwwkgh.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_193502_zpsc7uwwkgh.jpg.html)
Then after a bit more polishing got these two parts joined with a 5mm gap for the weld pool.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_193638_zpsdsqorrqz.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_193638_zpsdsqorrqz.jpg.html)
Plug in one hungry son and then this happened :D
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_194439_zpscwzlhmzz.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_194439_zpscwzlhmzz.jpg.html)
Now I have the main hoop ready for final tweaking ;)
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_201923_zps969npkdi.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_201923_zps969npkdi.jpg.html)
Here's the weld after a quick clean up
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150420_203205_zpsnbx5flsn.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150420_203205_zpsnbx5flsn.jpg.html)
I'm sure some racing rules will say I can't do this but tuff, it's done :p It's done in a place where the diagonal will be welded to anyway so in my mind it'll be flippin fine :cool:
solarman216
20-04-2015, 21:32
What is the diameter of the pipe Pete? looks a bit small to me, Rick
makeitfit
20-04-2015, 21:43
What is the diameter of the pipe Pete? looks a bit small to me, Rick
47.5mm o/d and 3.25mm wall :D
Seems big enough to me :lol
Looking good Pete:thumb2 slightly bigger tube would have been nice but i'm sure it'll work fine as a mounting point for your harnesses & i'm sure it'll still help stop the roof from slapping you on the head if there was a roll over:augie
solarman216
20-04-2015, 21:58
47.5mm o/d and 3.25mm wall :D
Seems big enough to me :lol
Fair enough, looks smaller in the pics, Rick
makeitfit
20-04-2015, 22:20
Fair enough, looks smaller in the pics, Rick
It's the distance mate, we're very far away from you here :lol
makeitfit
21-04-2015, 23:33
Didn't get much time tonight darn it so just a little update for you .
Made a rough template so I could bend some more tube for the harness bar. It's to keep the harness angle correct over my shoulders don't you know :thumb2
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_190544_zpsrdr9wzo9.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_190544_zpsrdr9wzo9.jpg.html)
I marked up the centre line and then what I calculate to be the correct distance to the centre of the bends radius ,ish :rolleyes:
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_191301_zps2eyukpec.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_191301_zps2eyukpec.jpg.html)
After a bit of pumping I got this bit of sh1te :o Turns out to be a tad more tricky than I thought to get a tidy bend , but hey ho it's still uber strong, just not 1st class .
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_193113_zpsxbdiicyx.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_193113_zpsxbdiicyx.jpg.html)
Next one needs a bog roll innard tomake a template for the pipe shape to join another pipe shape . Pipe notchers are so gay :lol
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_193437_zpsgi3f7n0n.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_193437_zpsgi3f7n0n.jpg.html)
Offer bog roll upto the roll bar at the ht reqd and sribe a pencil line just like this ;)
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_193551_zpsf2y6sour.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_193551_zpsf2y6sour.jpg.html)
Fold in half and cut the arc so it fits like this :D
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_193741_zpsitkoqlj3.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_193741_zpsitkoqlj3.jpg.html)
Put the bog roll back on the tube, mark and cut . Then grind back to suit .
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_194115_zpsjgjjkzup.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_194115_zpsjgjjkzup.jpg.html)
Not long after I got the harness bar to fit a treat . The other end is good too but my arms aren't long enough to picture both ends at the same time :p
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150421_202455_zpsgmo56dmm.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150421_202455_zpsgmo56dmm.jpg.html)
I hope to have a short day again tomorrow and get some diagonals cut and welding done :naughty
Nice to see you've got the harness bar swept back as it'll mean the seat could be moved back a bit if the next owner has longer legs than you:augie
makeitfit
21-04-2015, 23:52
Oh yes, always thinking :thumb2
Looking good but are you not adding a x in the roll hoop?
makeitfit
22-04-2015, 09:31
Looking good but are you not adding a x in the roll hoop?
Not on this one, just a single diagonal from drivers head back :thumbs There may be some lower struts going in if I get time.
Not on this one, just a single diagonal from drivers head back :thumbs There may be some lower struts going in if I get time.
:thumb2 Driver will be plenty safe then :lol
Pete
When everything has settled down your end how much would I have to pay you to make a roll cage for mine?
makeitfit
23-04-2015, 09:32
Pete
When everything has settled down your end how much would I have to pay you to make a roll cage for mine?
I'm not sure yet mate, learning as I go . I need to experiment further with this bender to see if it's even viable.
Even so , it's cheap enough to get the tightest bends done for me.
I'll update you as and when I get done :lol
AlexD333
23-04-2015, 15:40
Pete
When everything has settled down your end how much would I have to pay you to make a roll cage for mine?
Its very cool, but is it necessary?
I guess more so for a short wheelbase as most of you guys are 2 seaters only :nenau
Its very cool, but is it necessary?
I guess more so for a short wheelbase as most of you guys are 2 seaters only :nenau
Yes he needs this Alex as Pete needs somewhere to attach his 4 point harnesses to:augie TBH a internal roll cage could easily be made up for a LWB but getting into the back seat could be a bit tricky depending on the design. The back seat on my LWB almost never gets used & i'd love to take it out but the missus has said no:doh
You can always go with an Exo frame, one on the outside, like some LRs, Alex has already made a start on his.
I can see the advantages of an exo frame, when going to supermarkets lol....from door dings...:doh
I wish mine had an angle iron skirt that came up from under the sills when you remote lock the doors.:augie
I like the idea of an external frame.
Done quite a bit of digging into what is involved and how they fit on a lwb and still keep the rear doors functional.
Have yet to find one fitted on a terrano but there must be one out there.
Barrbeast
23-04-2015, 22:49
Looking good Pete :D
Look forward to seeing it in May :naughty
Only 3 weekends left:thumb2
makeitfit
23-04-2015, 23:17
Only 3 weekends left:thumb2
Oh fook :eek:
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150423_170523_zpsxcawijib.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150423_170523_zpsxcawijib.jpg.html)
But the cage is progressing :D
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150423_181026_zpsnzylvrhk.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150423_181026_zpsnzylvrhk.jpg.html)
makeitfit
25-04-2015, 23:06
Top day at the welder :thumb2 Started off lining up the spreader plates
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_120833_zpsfloc6mi1.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_120833_zpsfloc6mi1.jpg.html)
They needed trimming a bit to suit my rather interesting floor terrain .
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_120849_zpskyxnnal9.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_120849_zpskyxnnal9.jpg.html)
Then it's back to the magic bog roll for some angle ometry :):) This is the 1st diag support.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_140918_zpsii2cmeau.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_140918_zpsii2cmeau.jpg.html)
After a little fettling with Mr Grinder I got this :thumb2
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_140958_zpsnc5lgkfy.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_140958_zpsnc5lgkfy.jpg.html)
Then plug in one son and weldering he goes :bow
Base plate to upright weld :naughty
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_153237_zpsugvtumnz.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_153237_zpsugvtumnz.jpg.html)
I cleaned up the wheel arch ready to receive extra strengthening plates for the diag
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_173158_zpsqixo3tdu.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_173158_zpsqixo3tdu.jpg.html)
Put another 50p in the meter and off we go again.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_184031_zpsu9kzu35j.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_184031_zpsu9kzu35j.jpg.html)
I made up a buttress to shoulder the diag like this.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_200857_zpsgj5ou3ga.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_200857_zpsgj5ou3ga.jpg.html)
and the boy showing off his penetration :p
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_200841_zpshqct4rg1.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_200841_zpshqct4rg1.jpg.html)
Then I set about scribing that to the arch like this
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_201406_zpslem5o9pk.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_201406_zpslem5o9pk.jpg.html)
Oiked out the side window so we could get a good look at the intersection and weld it.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_201958_zps7n8y3vbd.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_201958_zps7n8y3vbd.jpg.html)
Tasty :cool:
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_203642_zps2oy9vvv3.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_203642_zps2oy9vvv3.jpg.html)
That's about as far as we got tonight. Much fabricating done though and loads of extra strength welded in.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150425_210312_zpsik2qqlqq.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150425_210312_zpsik2qqlqq.jpg.html)
Hope the rain stays orff tomorrow and we might just get there :clap
makeitfit
26-04-2015, 19:54
What a stonking day :D A bit of a lot of wind so we did have some winnbreak action going on but managed this lot :rolleyes:
Same routine, bigger bits . First diagonal in.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_164747_zpst0vtwtax.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_164747_zpst0vtwtax.jpg.html)
The other half of the diagonal is a bit more tricky to get just right, but I've got the hang of my bog roll now ;)
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_174456_zpsoymmgupl.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_174456_zpsoymmgupl.jpg.html)
The last bit in and no pressure lol I had about 400mm left over :eek: No returns if this didn't work out !
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_183615_zpsyb79assh.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_183615_zpsyb79assh.jpg.html)
Here's a little detail of the boy's welding :sly
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_183326_zpsiwwm2rnn.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_183326_zpsiwwm2rnn.jpg.html)
Detail of the diag to strut join . No idea if this is MIA CIA or whatever legal but we love it :clap
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_183632_zpseork7bq9.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_183632_zpseork7bq9.jpg.html)
Now working on the under body plate and chassis strut . There will be a bit of cow mat in there to absorb vibration and avoid body cracks I hope.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_184935_zpsekfxgpja.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_184935_zpsekfxgpja.jpg.html)
Just need to work out a way to hold the spare next , but at least 35" fits, just
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_190324_zpsxazlugwj.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_190324_zpsxazlugwj.jpg.html)
solarman216
26-04-2015, 20:12
Cracking cage Pete, my only criticism is I would have taken it to contact the roof so in the event of a roll it would limit the roof jamming the doors, you may of course be planning on doing this anyway at the sides/top so as not to interfere with the roof escape hatch, but very nice job anyway, I would feel safe in it, Rick
makeitfit
26-04-2015, 20:26
Thanks Rick, now you point it out it makes perfect sense. I hadn't thought of that. I do want to reinstate the head lining and interior trim. So maybe a bolt in insert to the roof over the B post would be a good idea ?
Escape hatch is ofcourse clear :lol
A quick question, It appears you are fixing the body to the chassis, and the Roll cage to the body, then chassis.
But do you still have the rubber body mounts between the body and the chassis?
As if that was the case, I would expect metal fatigue around the welds around the mounting plates to the body, as the remainder of the body is free to vibrate because of the rubber body mounts.
Would you be better using solid chassis to body mounts, or do you have that already?
I am no expert in mechanical engineering, but just a thought...
I have seen similar vehicles where the roll cage went through the floor with a gap, and some rubber seals, and the roll cage bolted directly to the chassis, so there is no physical connection between the body floor and the roll cage or chassis.
solarman216
26-04-2015, 20:42
A quick question, It appears you are fixing the body to the chassis, and the Roll cage to the body, then chassis.
But do you still have the rubber body mounts between the body and the chassis?
As if that was the case, I would expect metal fatigue around the welds around the mounting plates to the body, as the remainder of the body is free to vibrate because of the rubber body mounts.
Would you be better using solid chassis to body mounts, or do you have that already?
I am no expert in mechanical engineering, but just a thought...
I have seen similar vehicles where the roll cage went through the floor with a gap, and some rubber seals, and the roll cage bolted directly to the chassis, so there is no physical connection between the body floor and the roll cage or chassis.
Nothing fixed to chassis mate all to body, Rick
solarman216
26-04-2015, 20:45
Thanks Rick, now you point it out it makes perfect sense. I hadn't thought of that. I do want to reinstate the head lining and interior trim. So maybe a bolt in insert to the roof over the B post would be a good idea ?
Escape hatch is ofcourse clear :lol
Yep sounds good to me, Rick
makeitfit
26-04-2015, 20:45
Indeed uncle Rustic there can be metal fatigue . I should have explained better. "Cow mat"is like conveyor belt stuff. Thick rubber mat with canvass layers in it. I'm cutting a piece of it to go between this plate and the floor . It will be sandwiched then and I hope give the same effect as the rubber body mounts. :thumb2
I didn't want the hole in the floor version as it's a devil to seal then and keep water out.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150426_184935_zpsekfxgpja.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150426_184935_zpsekfxgpja.jpg.html)
Nothing fixed to chassis mate all to body, Rick
Ahhh... that's what the cow mat stuff is for... a flexi bit under the body, but supported by that bracket attached to the chassis.
I understand that now.
Yes that should work well:thumb2:thumb2
Thanks.
That looks brilliant:thumb2
solarman216
26-04-2015, 20:55
When I made the reply to Rustic about the no chassis fix I had missed the bracket to chassis bit, but to be honest I think that is over the top, but hey ho what do I know, we all drive differently and have different formulas and goals so whatever all is good for what we as individuals need, Rick
makeitfit
26-04-2015, 21:03
When I made the reply to Rustic about the no chassis fix I had missed the bracket to chassis bit, but to be honest I think that is over the top, but hey ho what do I know, we all drive differently and have different formulas and goals so whatever all is good for what we as individuals need, Rick
Rick the local 4x4 trailing club insist the cage goes to the chassis !
Apparently part of some RAC spec and insurance requirement ??
I researched some versions on 'tinterweb using rather smart panhard rod bushes and brackets to locate the cage to the chassis.
We decided that having gone this far we might as well put the cherries on it :lol
solarman216
26-04-2015, 21:57
Rick the local 4x4 trailing club insist the cage goes to the chassis !
Apparently part of some RAC spec and insurance requirement ??
I researched some versions on 'tinterweb using rather smart panhard rod bushes and brackets to locate the cage to the chassis.
We decided that having gone this far we might as well put the cherries on it :lol
Unaware of such issues, so well done, Rick
Mrs uses that cow mat stuff to line the floor in her stable.
The stuff she has got is about an inch thick.:thumb2
Looking the biz by the way Pete :thumb2
:lol Not that the Mrs lives in a stable,her horse does :lol
Fantastic work Pete:thumb2 You might find getting the rear 1/4 panel trims back on a little interesting as there doesn't look a lot of room to get them back in. There is a rumour that Alex is on his way down to yours with a tin of hammerite to paint your roll cage for you:lol:lol:lol
makeitfit
27-04-2015, 22:53
Fantastic work Pete:thumb2 There is a rumour that Alex is on his way down to yours with a tin of hammerite to paint your roll cage for you:lol:lol:lol
I've left the door open for him :D
AlexD333
28-04-2015, 06:27
I've left the door open for him :D
See you soon :naughty :augie
See you soon :naughty :augie
He won't be stopping long...in fact he might not be stopping at all...he has no rear brakes lol...
:lol
He won't be stopping long...in fact he might not be stopping at all...he has no rear brakes lol...
:lol
:lol :lol :lol :lol :lol
makeitfit
11-05-2015, 21:58
Another long day at the chassis face today :freak3:
However, the roll cage to chassis mounts now done. Cut a bit of conveyor belt to act as an insulator between body and mount.
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150511_201156_zpsgaobgpq0.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150511_201156_zpsgaobgpq0.jpg.html)
Welded up the brace ;)
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150511_201058_zpswugfph2e.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150511_201058_zpswugfph2e.jpg.html)
Then after some serious wind break construction the boy got it welded in place :clap
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150511_204036_zpssmmbuxla.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150511_204036_zpssmmbuxla.jpg.html)
That ain't coming off in a hurry :naughty
exosteve
11-05-2015, 22:17
thats kin nice welding
makeitfit
11-05-2015, 22:45
thats kin nice welding
Amazing considering the ruddy wind :D The boy wasn't impressed lol
At least I can get the gas tank in again now. All the welding sorted so less chance of kaboom :eek:
http://i667.photobucket.com/albums/vv36/daudwpsyn/20150511_205732_zpslho8yn7y.jpg (http://s667.photobucket.com/user/daudwpsyn/media/20150511_205732_zpslho8yn7y.jpg.html)
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