Swapshop 2004 STi Rally Car Rollcage

[LTBlackBird]

just gotta hope he'll never test the build strength haha

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[ciper]

Please tell me you have before and after weights!

[LENNYKIRK]

What about the door sill bars?

http://www.rally-america.com/info/2008_Rollcage.pdf

[DCRallyDave]

Rally America is not the sanctioning body in Canada. CARS rules are here:

http://www.carsrally.ca/CARSRally/Po...RS_2009_En.pdf

[DarkKnightBaku]

nice cage also curious of weight difference

[goofball]

Originally Posted by madmax718

if your good with a mig, it can be just as strong- Somewhere I thought that they were supposed to be tigged, or at least the root pass...

Not to call you out, but safety stuff is serious business. Most mig wire has a high silica content that can leave voids of glass depending on how weld is applied (machine settings, technique, etc). Tig leaves a more homogeneous profile that is less likely to crack due to inclusions. That's why they are no structural certifications in solid core mig. Juke'n and jive'n through through the whoops and woods at 100mph requires a cage that can hold together with a little flex. Again, I'm not trying to poke you in eye...

[barkley2-6]

I would have gone with black instead of the blue, but looks good.

[urabus555]

Originally Posted by goofball

Not to call you out, but safety stuff is serious business.

Theory is fun!

But that's a safe AND legal cage.

You can quote textbooks and whatever you'd like. The truth is, a well made cage - MIG'd - will hold up just fine in a rally car. The tubes will break before the welds. Design and good welds are required, yes, but MIG is just fine for this.

[urabus555]

Originally Posted by DarkKnightBaku

nice cage also curious of weight difference

If it's a CARS legal cage, that is a combination of 1.5" and 1.75" DOM (0.095 wall IIRC).

The tubing weighs 1.3lbs per foot and 1.7lbs per foot, respectively.

[urabus555]

Originally Posted by LENNYKIRK

What about the door sill bars?

http://www.rally-america.com/info/2008_Rollcage.pdf

All that really shows is two doorbars (which are required) but, they can be installed in a few different configurations to be legal. NASA is the only (NA Rally) Sanctioning Body to require sil bars (IIRC).

[urabus555]

Originally Posted by wkderf

im kinda curious:

what diameter piping is that?

has this cage been tested / certified?

and from what I can see, there isnt any provision for mounting the shoulder portions of a harness. how will you be handling that?

CARS (Canadian Association of Rally Sport) requires the use of 1.75" tubing for the main structure (very specific) and 1.5" for other tubes.

The cage meats the CARS (i.e. FIA article 253) requirements for cage design. FIA Article 253 can be found easily online if you're still curious.

The shoulder harnesses can be mounted on the tube between the rear shock towers. This is a less popular design lately. HANS requests that harnesses are intalled within 8" of the seats backs for optimal sfety for their product. But, if further, they ask you to cross the harnesses.

[urabus555]

Originally Posted by Darcros

What class and cert is that cage?

Other than missing the required gussets in the doorbars (two per door) and one more in the main hoop "x", that cage is FIA legal.

[urabus555]

Originally Posted by Darcros

it looks nothing like a rally america cert

It may get a CARS logbook, but it is exactly what RA is looking for. Both RA and CARS use FIA Article 253.

[urabus555]

Originally Posted by madmax718

if your good with a mig, it can be just as strong- Somewhere I thought that they were supposed to be tigged, or at least the root pass...

A lot of the confusion of the TIG vs. MIG thing stems from old rules. In the past, you could build cages using Chromoly Steal. Chromoly should be TIG'd.

Now, cages North America must be made of mild steal. Much easier to weld safely and consistantly.

The only real difference between a MIG'd cage and TIG'd cage is that with MIG, it is possible (for an inexperienced welder) to weld tbes together and have the weld look good, but have no penetration of the weld. Not an issue with a skilled welder!

With TIG, it's not really possible to have a good looking weld, and bad penetration. Good looking TIG welds are (99.9% of the time) good welds.

(IMHO of course!)

[goofball]

First of all, I apologize the op for not saying that the job was very nice and that I was not questioning anything done in the pictures. I was only trying to point out that mig welds can potentially fail due to inclusions from the silica. Like all art and most science, you have to go your own way. Suture self...

[urabus555]

I was just trying to point out that this is not 'structural' welding. even if the bead has microscopic impurities, the tubing will still fail before the weld. We are talking about material that is 0.095" thick.

MIG may not be suitable for many different applications. But it is suitable for cages. World Rally Cars (lots of engineers behind those things) have been know to sport MIG'd cages...

Originally Posted by goofball

Suture self...

[marchetta070]

very nice, how much would it cost for someone to bring in a car and get that done?

[RS22b]

our cage held up just fine with a MIG'd cage...



5x rolled at right near 90mph...

[RedefinedTR]

^ LOL the Broken Motorsports on that car says it all!

[rey_vibora]

that is one sick roll cage. you can eat of it.

[dr3w]

Very nice cage, and it coming from there I'm sure its built just as strong as it looks.

[Nate_1990]

Looks very very nice good work =]

[JDMspecC]

This is one of our car, It was a mig welded roll cage.

[i<3mylegacy]

woahh not cool

[EJ22T303]

the cage looks good on the first page