Roll cages.... where to start?

[ned]

Hi all, so I want to build a roll cage for my truck. Have been advsed that tube is better than square, due to it being stronger for the same weight.

I tried to use a pipe bender before and bent either end of a straight length of tube. I quickly realised its not that easy to get the exact same angle on the opposite end, not easy to do it by eye anyway.

Anyone have any tips on where to start? Youtube vids are going to be the way to go on this one, I would imagine.

Also going to need a decent tube bender, guy I was asking here in Ireland said 2 inch is a good size. But what wall.... lol so many questions.

 

[God mode restorations]

Most roll cages are cds mild steel or chromoly. And you will need a good quality tube bender. It's not something that should be attempted by a novice. Not saying you are but it's a complicated task that requires the correct care in its fitment and welding .

 

[rory1]

Get hold of the MSA blue book, this gives the regs for cages for motorsport within the UK. It gives you a good idea of the basics Even if your not planning on using the vehicle competitively

 

[Arc Tourist]

If you are looking to make a roll cage out of large diameter tubing, consider adding some air line fittings. Some guys I knew used to use the cage on their off road vehicles as a compressor tank so they could pump up their tires after airing them down for certain driving conditions; of course this was overseas, so may not be worthwhile except for on farmland here in the UK.

 

[Kent]

Cds tube is std today. We used to build in black pipe back in the 80s when I was involved with comp safari etc.
It served its purpose OK but scrutineer regs have changed constantly..
You don't want to be doing this if its for more than a look - shs ? No way !

 

[Ruffian]

What truck is it and is it going to be used for competitons or just hobby use.

Cds or t45 tubing is what majority of competition roll cages are made of,
But then again if just being used for off road use, we built a box section H frame setup in a mates discovery and never bent it even after a few interesting episodes.
(To the point we put a loop round it to hiab it/winch the roof when needed)

And again banger racers still only use adjustable H frames racing also.

 

[brightspark]

What truck is it and is it going to be used for competitons or just hobby use.

Cds or t45 tubing is what majority of competition roll cages are made of,
But then again if just being used for off road use, we built a box section H frame setup in a mates discovery and never bent it even after a few interesting episodes.
(To the point we put a loop round it to hiab it/winch the roof when needed)

And again banger racers still only use adjustable H frames racing also.

or a cutdown acro prop behind the seat jacked up

 

[Ruffian]

or a cutdown acro prop behind the seat jacked up

They frown apon that now.

 

[armalites]

You need to watch "The Fabricator" on youtube, has a series on tube bending. It's very interesting, none of it is rocket science it's just simple processes/maths keeping to a set of rules.

If you are talking 2" tube then you will most likely be need hydraulic power. To do a proper job you will at least be looking at a JDSquared 3 or 32, once you buy a bender, stand,2" die/follower you be close to a £1k before you buy the hydraulic conversion bits.

They don't come available second hand either for some reason. Given how many they sell you expect there to be a few second hand ones about.

 

[cocker]

Chopper builders handbook has a set of free downloadable drawings if you want to make a jd 2 .

 

[Ruffian]

Chopper builders handbook has a set of free downloadable drawings if you want to make a jd 2 .

That would be interesting,

 

[ned]

cheers guys ) Primary target is to build something that allows me to have the truck fall on its side. and not damage the doors or wings.

Had a look at those JD tube benders. Those are lovely.

Going to have a look at that youtbe channel next, thanks. Had not considered building it for competition, depends on whats involved, or am i even capable of that, lol. This is hobby stuff so not killing myself at all.

I notice a lot of mogs have this style structure and i like it.

So, if you roll it, hopefully onto a flat surface.... ..., it will sit on these edges below

I was watching vids on youtbe and quite a few mogs have that design, I'm going to go find some build threads.

 

[ned]

I watched some of the vids by the fabricator on youtube, didnt take it all in, will study them closely when going about it, - but yah, looks like a go-er, looks do-able.

I cant tig weld though, just mig and arc, hoping this isnt going to limit my choice of steel. If it does, I might have to learn.

 

[8ob]

Ned 63mm x3mm wall thickness (2" nominal bore waterpipe) works well in a staffa type hydraulic bender. Its what we use on everything that needs guarding up, its also easy to weld.



And more than strong enough when 8 ton of tractor and attachment leans on it when things go mammaries up

 

[rcx132]

At £10 per bend and £3 per notch I was thinking of getting my cage done by laser place.

 

[rcx132]

May have been £15 per bend. Can't remember exactly.

 

[ned]

8ob that looks like a fun job. Cheers for the recommendation ) rcx132 that certainly is an idea.

8ob the jd type have an angle measure built into them, do the Staffa type? I don't remember there being one. You're obviously well able to use the staffa type.

 

[Turbo]

By the time you buy the proper tube, a decent bender, your time and account for the scrapped pipe when you mess up a bend (and you will!) it will probably be as cheap to get it built by firm who builds roll cage. There are several all over Ireland, here are some links.
https://www.facebook.com/Wishart-Motorsport-Fabrication-202754859748027/ - very highly recommended but he's very busy!
https://rmsmotoring.com/forum/threads/best-company-to-get-a-roll-cage-made.202780/ a few names in this thread.

I would suggest you try contacting some clubs who run 4x4 off road trials & find out where they get their cages made.
http://www.4wdni.co.uk/
http://leinster4x4.ie/wordpress/

 

[armalites]

By the time you buy the proper tube, a decent bender, your time and account for the scrapped pipe when you mess up a bend (and you will!) it will probably be as cheap to get it built by firm who builds roll cage.

This is absolutely true but if you make everything about time/money you'll never do/try anything.

I have friends who earn less than me and seem to go on a £4-5K holiday every year. For a quarter of that I could get a bender with and die and have way more fun bending some tube than I'd ever have sitting on a beach or buy a pool for a week. I appreciate that a holiday would be for the whole family but just putting things into perspective

The JD benders are so sort after the suppliers in the UK are often sold out so you would probably get 75% of you money back easily if you sold it.

 

[8ob]

8ob that looks like a fun job. Cheers for the recommendation ) rcx132 that certainly is an idea.

8ob the jd type have an angle measure built into them, do the Staffa type? I don't remember there being one. You're obviously well able to use the staffa type.

Ned you dont need anything fancy to bend up roll bars if using 63mm x 3mm tube, the more you can bend in one piece the less you need to weld which has to be a better job. Staffa of JD will do the job but will differ in the approach. JD type benders work off tube center lines while staffa type crossbow benders work off bend centers. I will take some snaps of both so you can see what I am on about.

Bob