Roll cage welding

[rkde]

Hi

Just after some advice on wire, I am going to be welding in my roll cage soon which is OD45mm and a wall thickness of 2.6mm CDS what are the thoughts for the wire? 0.8>?

I may TIG it but I am not sure yet and I will ask tig, what size tungsten and filler? 1.6?

Thank you for your time and help

 

[Scamp]

When I was building kitcar chassis we just welded the roll bars and cages up with the MIG on 0.8mm wire. Never had one fail and some of our customers did a pretty good job on the crash testing side of things.

 

[fordman]

Have you the experience?

I think that if you need to ask these questions about putting together what is after all major piece of safety equipment, you need to take a step back and ask yourself "Am I experienced enough to weld a roll cage together safely?". I'm on rebuilding a MK2 Escort, and although happy to weld panels and strengthen the shell, I have a professional welder/fabricator lined up to do the roll cage.

 

[Vdub lover]

you would be best using A MIG for the cage with .8 wire, I just had a quote of £850 for a basic cage (race spec) upto £1850

 

[rkde]

Lots

I had quotes from £700 through to £1600 for a full kit form. The best price was from Andy Robinson race cars. In the end though I decided a full cage was too big for my car and have currently got a half cage in the post, wish it would hurry up and arrive!!

Though for a standard car they are not too costly. Its also when you choose T45 over CDS which makes a big difference, and when they weld it in then the cost is huge...

I will get me some 0.8 wire and have it reckless

 

[rockjock620]

I think that if you need to ask these questions about putting together what is after all major piece of safety equipment, you need to take a step back and ask yourself "Am I experienced enough to weld a roll cage together safely?".

Agreed. I was going to suggest the same - does the OP want a "roll cage shaped object" or does he want a roll cage to save his life? World of difference.

 

[rkde]

Don't see why not, I had my welding tested and am OK to weld to an FIA standard for cage certification I was after some advice really to see what everyone else does.

I did the 3 tube test where they get tested on a tensile test and it passed, neat welds, and good penetration. I was welding a slightly smaller tube than this but it was more what wire should I use, when I did the test it was on 0.6 and I think I could get away with it but just wanted some advice. I will go with 0.8

Also the cage is only for a harness mount and not designed to take a roll into account though I am 100% sure the main section will

 

[rockjock620]

OK fair do's then!

 

[rkde]

However I should have said, good advice and thank you for suggesting it. If I didn't know your advice would be very valid and I appreciate it

 

[gavuk]

Don't see why not, I had my welding tested and am OK to weld to an FIA standard for cage certification

what kind of test did you have to sit?...not intending doing any myself but i'm sure others would be interested ...

 

[rkde]

Sorry, most cage companies do it if they are FIA, MSA approved, depends on who makes your cage, they should be able to offer the test. Custom cages do a test for reference best advice is just to ask your cage supplier if they can do the testing for you

http://www.customcages.co.uk/roll-cages/certification

I did my testing through a company I used to work for but its the same thing. Not sure who they directly sent it to though... I do not have a cost for it either but I am sure the company linked would be able to help

 

[gavuk]

interesting welding a roll cage videos of the guys installing the cage ,i could see loads of places for problems...lol....lots of plasma cutting to fit as well, .......what did make me smile was the test peice...set up on a bench to achieve.... against the restricted access,and positions actually encountered in fitting in a car .....i'd be quite confident to do the test piece not so confident making all the welds in the car look as good though

 

[rkde]

A cage that size would make me pooh myself, my cage can be welded out of the car then dropped in, thank god but yeah that huge cage would be a huge job

 

[squazy84]

Agreed. I was going to suggest the same - does the OP want a "roll cage shaped object" or does he want a roll cage to save his life? World of difference.

what is it about people, they always love saying this kind of crap, its a real human thing is'nt it, we just take every oppertunity to sxhit on another person with the possibility of looking smart thrown in for good measure, we are a race of tossers are we not? look im even doing it myself lol

 

[rkde]

Yep we are all tossers me included. Yes its a human thing, it must be my dog doesn't do it but he can lick his knackers I cant lick mine, what has the dog got to worry about...

Give and take, we all love the internet and the fact we know nobody