Rollcage Installation w/pics

[wedge]

Here's some of the prep work we had to do:

(click on thumbnails for full size)

Alex removing the windshield. We tried to remove it without breaking it. But that turned out to be too difficult a task. Now we need to buy a new one...

http://x2.putfile.com/3/8809442990-thumb.jpg (http://putfile.com/pic.php?pic=3/8809442990.jpg&s=x2)

I had to grind and sand down to bare metal the shock towers and in the corner behind the front seats. Those are the places we needed to weld the mounting plates on.

http://x2.putfile.com/3/8809463112-thumb.jpg (http://putfile.com/pic.php?pic=3/8809463112.jpg&s=x2)

http://x2.putfile.com/3/8809470984-thumb.jpg (http://putfile.com/pic.php?pic=3/8809470984.jpg&s=x2)

While Peter used the plasma cutter to actually make the rollbar mounts.

http://x2.putfile.com/3/8809474758-thumb.jpg (http://putfile.com/pic.php?pic=3/8809474758.jpg&s=x2)

Now, here's Phil (our master welder), welding the mounting plate onto the rear strut tower.

http://x2.putfile.com/3/8809481848-thumb.jpg (http://putfile.com/pic.php?pic=3/8809481848.jpg&s=x2)

http://x2.putfile.com/3/8809485267-thumb.jpg (http://putfile.com/pic.php?pic=3/8809485267.jpg&s=x2)


Here's what they looked like afterwards:

Floor:
http://x2.putfile.com/3/8809492332-thumb.jpg (http://putfile.com/pic.php?pic=3/8809492332.jpg&s=x2)

Rear Strut:
http://x2.putfile.com/3/8809495853-thumb.jpg (http://putfile.com/pic.php?pic=3/8809495853.jpg&s=x2)

Front:
http://x2.putfile.com/3/8809502579-thumb.jpg (http://putfile.com/pic.php?pic=3/8809502579.jpg&s=x2)

And now some of the finished bars:

Main hoop:
http://x2.putfile.com/3/8809510047-thumb.jpg (http://putfile.com/pic.php?pic=3/8809510047.jpg&s=x2)

Windscreen:
http://x2.putfile.com/3/8809512834-thumb.jpg (http://putfile.com/pic.php?pic=3/8809512834.jpg&s=x2)

Roof:
http://x2.putfile.com/3/8809515616-thumb.jpg (http://putfile.com/pic.php?pic=3/8809515616.jpg&s=x2)

Rear Backstays:
http://x2.putfile.com/3/8809525187-thumb.jpg (http://putfile.com/pic.php?pic=3/8809525187.jpg&s=x2)

Doorbars:
http://x2.putfile.com/3/8809531894-thumb.jpg (http://putfile.com/pic.php?pic=3/8809531894.jpg&s=x2)

http://x2.putfile.com/3/8809534852-thumb.jpg (http://putfile.com/pic.php?pic=3/8809534852.jpg&s=x2)

But it's still not done yet. We still need to install the harness bar in the main hoop. But we can't do that until we put an 'X' in the Backstays. But we can't put in the X until we remove the rear window. So we have to wait until Monday, so that we can call in an expert who can remove it without breaking it. The rear window is MUCH more expensive than the front. After that, our rollcage will be finished. Then I can paint it, and put everything back together. Then the car will be ready to rally!

[subterfuge]

Nice!!! :thumbup:

[Piotrov]

Sweet!! its starting to look like a Rally monster :D
Great Job Man! :2thumb:

[S E X Y L I C A]

WOW, thats A S HI T LOAD OF WERK!!!!!

[fineline]

nice work!!! :thumbup:

[IceTeal]

You cant just run some piano wire around the edges of the window? It has been my experience that you can just feed it through, and pull it along the edge until the window comes free.

[Manny]

nice.........................

[wedge]

You cant just run some piano wire around the edges of the window? It has been my experience that you can just feed it through, and pull it along the edge until the window comes free.

Maybe, but that would take forever. The glue that holds the glass on is as hard as rock. Time is money man! It's cheaper to be wasteful and break it out, and buy a new windshield.

[AlanO]

Are you going to tie the cage to the front strut towers?

Our Subie is basically twisting itself around the cage. If it had been better designed it would have another 50 rallies left in it.

Looks good! Going to be ready for Bear?

[wedge]

No we didn't bother putting it through the firewall. That would be a ton more work. Besides which, we ran out of tubing... And I need to save SOME money for tires and gas etc. :gap:
I am at least going to brace the front strut towers just to each other. And I'm going try to design the skid plate in such as way that it will act like a lower brace as well. Also we're going to try to do as much seam welding as possible. This car will be plenty tough!
Even if the chassis starts to wear out, it won't matter to me. This isn't a long term project. I only plan to keep this car for 2 or 3 seasons. Then sell it, and move up to a better car. This car is just going to be a rally beater, it's perfect for us beginners to learn the ropes.

The current plan is to be ready for Bear. Then again we also expected to be ready for Neige, but that didn't quite work out...
At least now things are going well, there's absolutely no reason why we shouldn't be able to finish it all in time.

[brandon6976]

is that your car matt ?? I thought your car was red ?

[wedge]

is that your car matt ?? I thought your car was red ?

My car was red. My glorious red Paseo. I'm sure you are aware what happened to that car right?

This is my NEW Paseo. I have no emotional attachment to this one, so I get to beat the hell out of it without feeling guilty. :devil:

[Piotrov]

Im sure you will get to loving this one after a few rallies :D

[wedge]

Im sure you will get to loving this one after a few rallies :D

Only if it survives without blowing itself up. And even then, that's a big IF.

:wack:

Time will tell.

[wedge]

Well, the cage is done, here's how it looks now:

http://x2.putfile.com/4/9220360048-thumb.jpg (http://putfile.com/pic.php?pic=4/9220360048.jpg&s=x2)

http://x2.putfile.com/4/9220370575-thumb.jpg (http://putfile.com/pic.php?pic=4/9220370575.jpg&s=x2)

http://x2.putfile.com/4/9220373938-thumb.jpg (http://putfile.com/pic.php?pic=4/9220373938.jpg&s=x2)

http://x2.putfile.com/4/9220380838-thumb.jpg (http://putfile.com/pic.php?pic=4/9220380838.jpg&s=x2)

[Piotrov]

Very nice! Are you re-painting the car?
Also you got sponsors or you doing this completly on your own?

[DONTPULLMEOVER]

I am curious to know how much extra weight that adds to a car like that?


:?

[Methanoxide]

Mmmmmmmm.. Paseo with a roll cage!

And as for the extra weight, I don't think he has an option BUT to install a cage in order to compete. :towel:

[DONTPULLMEOVER]

Mmmmmmmm.. Paseo with a roll cage!

And as for the extra weight, I don't think he has an option BUT to install a cage in order to compete. :towel:

I know that, the question was how much it weighed? :giggle:

100 Pounds? 60?

[wedge]

I know that, the question was how much it weighed? :giggle:

100 Pounds? 60?

Ummm... I dunno. I can tell you for sure that those bars are heavy. They're pretty small diameter, so they don't look like much. But they are a very thick gauge.
I doesn't really matter how much it weighs. The minimum weight required in the rulebook is the factory weight listed by the manufacturer. So now I can keep removing things until I am back down to the stock weight. With the whole interior stripped out, it really doesn't affect the overall weight by that much anyways.

[StewPiddass]

I had the opportunity to drive Matt's rally beast at the Solo2 school last weekend, though he is much (much) smaller than me so I hardly fit in his skinny ass seat and I was a little close and the harnesses were a mess... it felt very good, turn in was awesome, it is amazing what a cage can do to the rigidity of a car.

[Piotrov]

Matt offered to trade cars with me but i felt too intimidated to drive his car for some reason. :D He did get to show me what a pro can do with my car :2thumb:

[wedge]

it felt very good, turn in was awesome, it is amazing what a cage can do to the rigidity of a car.

And that's with the suspension setup for gravel roads. It would have been MUCH better with the suspension settings I had on my red Paseo.



He did get to show me what a pro can do with my car

Pro? hehe :oops: I'm flattered.