Brett Richmond

I have a roll bar that I am about ready to install in my C4, what is the best way to notch the support bars to be welded to the main hoop. I don't have access to any heavy duty machine tools to notch the bars. Should I use a jigsaw or what???

davidfarmer

if you bought a kit, then I would expect them to already by cut out. If not, you need to find a plasma cutter or torch. Ugly, but effective.

Using a saw will be difficult

Brett Richmond

It is just a universal 8 pt kit from Autpower.

turtlevette

regular old 4" hand grinder worked well for me.

you using a stick welder?

bsim

Uh, a tubing notcher would work.

I'd have serious concerns about the quality of the tubing welds if the person performing said welds never notched tubing before.

Gary04Z06

If its not pre-notched, you bought some pipe.

AU N EGL

Safty and roll cages are nothing to experiment with.

fatbillybob

you can use a 4" angle grinder and a 1/2 round file to get joints that look like this preweld...

The better you fishmouth the joints the better the cage. And then like this postweld...


You can do this with a MIG like I did if you are a good welder and can get good penetration with good power. TIG is fool proof as it naturally gets more penetration. MIG has the advantage that it is like squirting toopaste and you can weld upside down easier. But the danger is birdpoop surface welds with no penetration. Just becareful to get good penetration if you MIG. Go to http://www.pipemastertools.com/ to get a great tool that helps you transfer joint outlines. Use a machinist white dyechem paint marker or light color sharpie. Also notice how I have boxed into the unibody. Your cage is only as good as what it sits on so make sure the feet distribute loads well and over a reasonable surface area. My boxing was done since I am using sill tubes too. This is not the only way but one good way.

Brett Richmond

Thanks for all the reply's, I knew I could get the answer here.

HeyFred

Here is is the notcher I use:
http://www.jd2.com/TN100/TN100_Features.htm

Keith

bsim

For the more budget minded.

Vetracr

DON't FORGET TO REMOVE THE ECM IF YOUR STICK WELDING AND USING THE CHASSIS AS A GROUND. OTHERWISE, ITS FRY CITY!!


Larry