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Old 9th February 2010, 16:47   #16
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Default Bull bar/Roll cage fabrication

Starting tis topic for suggesions and help to source contacts to have a bull bar/Roll cage fabricated

I'm currently looking for some good fabricator, who can fabricate a bull bar/ roll cage for my Jeep. I'm from bangalore and i'm trying to source someone in
Bangalore, who can do it in 2 1/2 " ( two and a half inch ) pipe. I did come across someone who heats the pipe and then bend it for the roll cage.
But, those will not give a good finish at the bends. So, i'm trying to find someone who has the cast to bend the 2 1/2 " pipe for a good finish.

The same person that i'm refering to, does it in a 2" pipe and bends it with the cast but dos not have a cast for the 2 1/2 ", but I want a 2 1/2 " one that will blend with my jeep.

Request the guru's out here to give your suggestons or help me with contacts you are aware of for this to complete this on my Jeep for me.
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Old 10th February 2010, 11:11   #17
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Bangalore, who can do it in 2 1/2 " ( two and a half inch ) pipe. I did come across someone who heats the pipe and then bend it for the roll cage.
Don't go to him. Heating will cause that area to become weak. The pipe has to bent cold on a pipe bending machine.

I'll post more details in a couple of days.
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Old 10th February 2010, 11:24   #18
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Originally Posted by raghu4222 View Post
Starting tis topic for suggesions and help to source contacts to have a bull bar/Roll cage fabricated

I'm currently looking for some good fabricator, who can fabricate a bull bar/ roll cage for my Jeep. I'm from bangalore and i'm trying to source someone in
Bangalore, who can do it in 2 1/2 " ( two and a half inch ) pipe. I did come across someone who heats the pipe and then bend it for the roll cage.
But, those will not give a good finish at the bends. So, i'm trying to find someone who has the cast to bend the 2 1/2 " pipe for a good finish.

The same person that i'm refering to, does it in a 2" pipe and bends it with the cast but dos not have a cast for the 2 1/2 ", but I want a 2 1/2 " one that will blend with my jeep.

Request the guru's out here to give your suggestons or help me with contacts you are aware of for this to complete this on my Jeep for me.
Buddy you are trying to build a roll-cage, which is a safety device. So use Seamless Pipes and get the cage made from a fabrication shop which has a pipe bending machine, even a manual one will do [these shops are cheaper to work with compared to the CNC onces], as long as the work is done on a bender.
Pipe bending machine help bending pipe without crimping them on the inner side and keeps the strength of the pipe. Heating will cause fatigue points at the bends and will be very week at those point.
And seamless pipe are strong for this type of application compared to seam welded pipe. Also remember to TIG weld the cage, this will give the cage greater strength, the joint is as strong an the weld.

Last edited by dinar : 10th February 2010 at 11:27.
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Old 10th February 2010, 12:31   #19
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Absolutely correct dinar.

Although there is a debate regarding a MIG or TIG weld. (MIG welds ofcourse are more ugly looking).

So raghu, remember the functions of a roll cage:

- enhance occupant survivability and reduce injuries during a roll over.
- can also provide substantial mountings for safety harnesses and seats
- substantial chassis stiffening that a properly triangulated roll cage can provide. However, this last point is good for rally cars where stiffness is good for high speed handling; in offroading, a little bit of chassis flex is desirable. (correct me if i'm wrong).

Thus, when you are designing the roll cage, please follow the following to the "t":

The tubing must be 44.45mm dia x 2.6mm thickness for main hoops and forward legs, and 38.1mm dia x 2.6mm thickness for all other members. The tubing material is low carbon, cold drawn seamless or cold drawn welded tube which is normalized to provide yield strengths of between 400-500 MPa (source: VicRoads Information on Roll Cages and Rego)

The roll bar must be padded if you are making an internal roll cage

I'm attaching a pdf file, read it very very carefully.
Attached Files
File Type: pdf VSI28.pdf (750.4 KB, 857 views)
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Old 10th February 2010, 12:51   #20
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To, add to that, i just found a very helpful hint:

Recommend that you start your roll bar project by buying PVC pipe and bends in the size you have selected for your actual bar to create a mock-up. First mount your seats in the position you will be driving in. Driver comfort is of primary concern. Set up your PVC tubing and check for clearance around the driver's head. No tube member should be located where the driver's head can make contact in the event of an accident. With the driver properly belted in, you will need at least two inches of clearance under the top of the bar to the top of the head.

Source: Harold Pace/autoMedia.com
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Old 10th February 2010, 14:12   #21
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......where the driver's head can make contact in the event of an accident. With the driver properly belted in, you will need at least two inches of clearance under the top of the bar to the top of the head...
Exactly why the CJ340, Classic type Roll bars were nearly a foot behind the Driver's Head. They looked neat and also saved a bump too many. My Jeep has a crappy after-market-fabricated one and it was more than closer to my head to give a nasty bump over a speed bump.

- is the stock CJ340/Classic Roll Bar still available?
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Old 10th February 2010, 14:46   #22
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- is the stock CJ340/Classic Roll Bar still available?
Like Below, courtesy Suresh Stephen's Jeep

Name:  CJ340 RollCage.JPG
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Old 10th February 2010, 18:17   #23
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I think a roll cage (atleast 6 point) is very essential. My classic has just a single roll bar and i think it is not adequate.

Ideal would be to weld a roll cage and be done with it but i kinda like the looks of the car and want to fabricate an external roll cage which can be a simple bolt on and can be removed and dismantled when not OTRing.

I need to know the following:

- What is the min and ideal diameter pipes to be used?

- What is the gauge of the pipe (min and ideal)?

- At what points of the body can the cage be bolted on?

- Should those parts of the body be strengthened and how?

- I don't have a garage to store this, so i need to make the cage out of bars which will bolt on to right angle elbow bends. Is it ok to do so strengthwise?

- How do i connect it with the existing roll bar in the center?

- Any suggestions on design for the classic? I have gone through enough pics on the web, so please don't cross post in general.
Hi Tejas Ill be building one for the classic very soon but the non removal one. If you want to make a removal one make a totally new roll cage other than the company one so you can fit it during otrs. Another option is make a half front rollcage and bolt it to the center of the original one. the most important thing is that the base should be connected to the chassis. All pics from the net dont help just search for projects build- up photos. Ill be using a 2'' diameter and 2.5 mm thick seamless hydraulic pipe for the roll cage.
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Old 10th February 2010, 18:28   #24
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Hi Tejas Ill be building one for the classic very soon but the non removal one. If you want to make a removal one make a totally new roll cage other than the company one so you can fit it during otrs. Another option is make a half front rollcage and bolt it to the center of the original one. the most important thing is that the base should be connected to the chassis. All pics from the net dont help just search for projects build- up photos. Ill be using a 2'' diameter and 2.5 mm thick seamless hydraulic pipe for the roll cage.
I dont think connecting the roll cage to the chassis is such a good idea, the jeep chassis flexes a lot and impeding that will do no good.

Better to connect it to the body with wide square flanges and sandwitch the body between both the flanges.

If you are really bothered about the roll cage punching through the body build a 8 point roll cage and connect all the legs with another smaller dia pipe running along the body and bolt it down.

If you need help James , let me know i have done it before on my own vehicle and can tell you from experience where you can improve the design.
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Old 10th February 2010, 18:51   #25
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If any one needs a good fabricator in bombay (borivili) i have a contact he will use a pipe bender machine to get the roll bar in shape hes got the dye for all pipes starting from 1'' to 5'' ,
For my jeep what he suggested was to first get mock up rods bent take the actual markings and then get seemless pipes and then bend them on the die according to the bent rod.

i am working to find out the costings for my 550 will let you guys know
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Old 10th February 2010, 19:12   #26
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Originally Posted by raghu4222 View Post
Starting tis topic for suggesions and help to source contacts to have a bull bar/Roll cage fabricated.
If you dont mind the cost try Sai colorium, they have modification dept who can do this for you. Pricing unlike the painting dept was on the higher side, this is what i understood. Also if you have contacts with rally boys get some contacts from them.
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Old 10th February 2010, 20:17   #27
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Like Below, courtesy Suresh Stephen's Jeep

Attachment 285255
I see one element missing in it. See my roll cage.

Name:  325151641_p7041044.jpg
Views: 3580
Size:  271.2 KB

And the one from the brochure...

Exterior roll cage for a 4x4-scan0002.jpg
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Old 10th February 2010, 20:34   #28
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If you dont mind the cost try Sai colorium, they have modification dept who can do this for you. Pricing unlike the painting dept was on the higher side, this is what i understood. Also if you have contacts with rally boys get some contacts from them.
I would suggest option 2 (rally boys) over Sai Colorium for this work. Sai does mod work but don't come as having this kind of mods as their core competency. They are more into DC kind of sheet metal mods
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Old 10th February 2010, 20:48   #29
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Ok listen to Khan he is the one who did the snooping around at that section

Try FRK racing on whitefield road, they might be able to help you with some rally contacts. Might even do it for you.
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Old 11th February 2010, 12:31   #30
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I would suggest option 2 (rally boys) over Sai Colorium for this work. Sai does mod work but don't come as having this kind of mods as their core competency. They are more into DC kind of sheet metal mods
Thank you Khan Bhai, but, i dont have any contacts on the option 2. Please share your suggesions and contact info if you are aware of any fabricator for the roll cage.

Thanks in advance
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