[svsantosh]

Final design is complete, now final welding and grinding is going on, hopefully ready by tomm evening.

[svsantosh]

Roll cage primer'd and painted black - DIY (210Rs for the whole job )
Co-Driver seat in place
Brake drums painted black and alloyz/tyres back on
Snorkel back on

Tomm should see the leaves recambered, minor mech work and alignment...

[PAVAN KADAM]

Originally Posted by svsantosh

Roll cage primer'd and painted black - DIY (210Rs for the whole job )
Co-Driver seat in place
Brake drums painted black and alloyz/tyres back on
Snorkel back on

Tomm should see the leaves recambered, minor mech work and alignment...

Sir, you could have done a lot with the roll cage design.

I feel your mechanic has just added weight, which is not good, do consider a little changes.

The front one can just be a "U" not touching the windshield, but a little over the widshield maybe by 2 inches, and the rear could have just sloped down a bit...

[Sudarshan]

Originally Posted by PAVAN KADAM

Sir, you could have done a lot with the roll cage design.

I disagree , there 'could' be N designs to go with , but if you look closely this is the most simple & practical way ( wrt ease of access vs strength ) to do a roll cage , agreed its not looking flashy

I feel your mechanic has just added weight, which is not good, do consider a little changes.

is there any other way ? I mean if you have to use a 2" or 1.75" dia & 4 mm thick pipe totalling to some 36 + feet ?

Am I wrong about the total length Santosh ?

The front one can just be a "U" not touching the windshield, but a little over the widshield maybe by 2 inches, and the rear could have just sloped down a bit...

can you please elaborate with a sketch ? especially the front " U " --I didn't understand

Sudarshan

[svsantosh]

Originally Posted by PAVAN KADAM

Sir, you could have done a lot with the roll cage design.

I feel your mechanic has just added weight, which is not good, do consider a little changes.

The front one can just be a "U" not touching the windshield, but a little over the widshield maybe by 2 inches, and the rear could have just sloped down a bit...

a - like? please post some rough sketches, there is one more 540 in paint shop...

b - mech had nothing to do with it, totally executed by 3 'commerce, IT and a doctor' guyz , regd the weight - its a swb, not much of pipe length was needed (as to a 5x0 class) and i was bent upon a 3-U roll cage, needed it for soft top to be complete. Rest was just ideas inside the head visualizing a few roll over situations. Thats what led to the diagonal in B-pillar over drivers head. Oh and its only a 2MM pipe, not a 4MM cold rolled seamless pipe!!

c - Front is a U, only extra is that left-right connection (Over dash) needed bcoz this is a CJ without A-pillar. EDIT - And I made sure the pipe doesnt touch the A-Pillar and give the irritating rattling noise!!

Originally Posted by Sudarshan

...but if you look closely this is the most simple & practical way ( wrt ease of access vs strength ) to do a roll cage

Thank you sirji...

agreed its not looking flashy

Few said the other way around, but no bother, I wanted safety.

Am I wrong about the total length Santosh ?

Measuring it today... will let you know by evening. I am guessing total length to be approx 45 feet, around 40-45 Kilos max.

[V-16]

Excellent positioning of the A Pillar Santosh. Unfortunately i will not be able to follow it as i want the doors and the soft top on my MM. Will have to think of something fast as it goes for the RC on Monday!!

[svsantosh]

Originally Posted by Sudarshan

....some 36 + feet?

610~ Inches or about 50 feet. A 20ft pipe (2" 2MM) is 17Kilos, so approx 43 Kilos of piping. Give or take about 2 kilos for base plates, 2Kilos of welding and 7kilos for rear angle-base plates - around 55kilos for roll cage. Now it does sound heavy... hmm. Whats is the industry standard for a roll cage weight? 30 max??

Originally Posted by V-16

Excellent positioning of the A Pillar Santosh. Unfortunately i will not be able to follow it as i want the doors and the soft top on my MM. Will have to think of something fast as it goes for the RC on Monday!!

Np, I just wanted to give you some ideas. PS - You cant do much on a outside-in design, meaning - you want to retain the soft top, so your imagination is already limited to those corners - the same head ache I had while roll caging the black 540, in a CJ, you have all the room you want, but dont go over-weight like mine!!

[Sudarshan]

Originally Posted by svsantosh

610~ == - around 55kilos for roll cage. Now it does sound heavy.

Round it off for 60 kg so?

Effects ( IMHO, AFAIK )

1) WRT payload capacity (carrying capacity ) of the Jeep - nothing --you are just carrying an extra person all the time ,

2) WRT Center of gravity --- firstly where is it in a 340 ? 1/2" above the floor ? Or at the seat base ? or at the seat level ? I don't think its above the seat base in a 80" diesel Jeep --- So it may have gone up for 2 " --- So ? --Nothing compared to the safety

3) you need a road test , especially the cornering at speeds but you have re-cambered the road springs -- keep that in mind

4) Seriously thinking its nothing compared to the safety it will give >> NOW FIT SEAT BELTS you will be having good overall protection


P.S. If you are having those longer shackles -- remove them , the ride will be under control

Sudarshan

[svsantosh]

Originally Posted by Sudarshan

1) WRT payload capacity (carrying capacity ) of the Jeep - nothing --you are just carrying an extra person all the time ,

Yep, that was my thought.

2) WRT Center of gravity --- firstly where is it in a 340 ? 1/2" above the floor ? Or at the seat base ? or at the seat level ? I don't think its above the seat base in a 80" diesel Jeep --- So it may have gone up for 2 " --- So ? --Nothing compared to the safety

Yes, need to check it.

3) you need a road test , especially the cornering at speeds but you have re-cambered the road springs -- keep that in mind

Leafs not yet, taking it slow, not in a hurry, need to open up alternator and starter motor for a checkup. so jeep still in mechs place, leaf specialist is across the road.

Seriously thinking its nothing compared to the safety it will give >> NOW FIT SEAT BELTS you will be having good overall protection

yep - 6 point - rally style over both shoulders and across the waist - howz that?

P.S. If you are having those longer shackles -- remove them , the ride will be under control

GONE!!! Sold them - best part, nearly at purchase price.

[Sudarshan]

Originally Posted by svsantosh

yep - 6 point - rally style over both shoulders and across the waist - howz that?

Frankly I havent fitted/tried these

but my thinking is they must open quickly, in emergencies ( wrt locking mechanism ) yet hold you in place under harsh shock .

I will suggest to go for the normal 3 point ones for now ( time being ) & then do some good research on the rally ones , I fear that there will be many a copy cat 'bling bling ' cheap varieties in the market , so you will need to find for some genuine ones ( the real 6 point ones )

also I think you will need a special seat assembly to go with these 6 point ones -- they wont easily fit with a normal seat ( IMHO )

So it looks like its going to take time till you find some genuine thing

Sudarshan

[SPIKE ARRESTOR]

Originally Posted by svsantosh

GONE!!! Sold them - best part, nearly at purchase price.

SVS, why did you get rid of them? Any specific reasons?

Spike

[svsantosh]

Sudhi - regd 6 point i had a idea of a combo seat belt (driver and co-driver side) on 1 side itself. One from the right B Pillar and the 2nd from the cross beam I have on B pillar - over the left shoulder. What say?

Spikey - ride was harsh, excessive rolling in corners and unstable at turns. Of course high C.O.G and fear of tipping over in sideways obstacles.

[Sudarshan]

Originally Posted by svsantosh

Sudhi - regd 6 point i had a idea of a combo seat belt (driver and co-driver side) on 1 side itself. One from the right B Pillar and the 2nd from the cross beam I have on B pillar - over the left shoulder. What say?

Man you need to study a lot on this -- if you fit some kind of a wrong contraption ( read unscientific ) you may land in to trouble at the time of an accident , some of your body parts will be tied & others free -- the result ? think over

Let me tell you my example , Me & my Jeep met an accident in 1997 . a fully loaded acid Tanker truck banged ( actually landed straight ) on the Jeep from behind .

It happened like this -- as I just took of after crossing a speed breaker -- I was in second gear at around 15 km/h - the truck took off from the speed breaker, lost control & landed straight on us & hit the back of the Jeep

This incident completely shattered every myth I had about accidents , It was a jolt of a life time , the seat's recline mechanism broke & the backs went flat -- that actually saved us from breaking our necks ( otherwise the neck could have got a severe shock as the back would have kept steady & in place- & the weight of the head acting fully on the neck -it had no head rests ) . My Jeep is a five door steel body , so had a lot more space to crumple -till anything could have touched us .

Moral of the story is , It happens all of a sudden , no time for reactions . It takes you by surprise & you are in hands of elements chosen by you ( the type of body- top , seats & belts etc )

So think deep its not easy as it looks

Sudarshan

[svsantosh]

^ Thx sir - will surely re-think about it. right now, even the regular seat belt on hold - homemin' wants the old (truck) MIL seats (no, not for the MIL ) but she finds it much comfortable (the 8-way adjustable is un-paralleled) for short drives than a sedans seat, back to drawing board!! I am lost now!!

PS - Leaf recambering over, looks good. Tomm the alternator and startermotor get their long due full disection and check-up. The bendix sounds' acting up and needs a look, also time to change the diodes in the alternator to acheive the max-60Ah rating yep, learnt the TATA 407 OE alternator pumps out 60Ah.

[Twinn]

Originally Posted by svsantosh

yep - 6 point - rally style over both shoulders and across the waist - howz that?

6 pointer!!! Where will you get those and what price do you plan to spend on them?

Reason I am asking is in the rallies we have 4 pointers of 5 pointer belts fitted on to the non recliners bucket seats, which holds you in the seats no matter how bad the crash is.

Unless you have a bucket seat these pointer belts are not advisable. could you share the pic of the same? I understand 4 points, 2 are from each shoulder and two from the waist, one in b/w the legs (for the 5 pointer), other?

Example = _\./_
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