SteveoBC
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Registered: 22nd Feb 07
Location: Bucks
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Was planning on making my own rollcage for my track car im building and need to know what the best size of pipe to use
ie- diameter, gauge of the metal that sort of thing,
going to weld it in myself and build it to my own design
including roll over bar, bars to the back suspension turrets, X section in the back also, bars going through the bulkhead to the front turrets and the bars following the door frame/a-post
and hopefully some removable door bars
if anyone can tell me the best type to use that would be really helpful, then i can get down the Hire Shop and rent a pipe bender and get cracking 
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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you will need a beefy pipe bender to bend the tubing properly, I use this:
ideally you want to be using mild steel with a 1.5mm wall thickness.
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STEvieXE
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Registered: 21st Jan 03
Location: Ballymena N.I.
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u make cages dave??
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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well I dont advertise that I do them as unless you do a lot of them theres not massive money in them. plus people always want them fully fitted and painted which takes ages.
I have done 1 in a mates car and will be doing one in my own car, lad that works for me has experience with them so I leave it to him.
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
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dave, wont an electric pipe bender be ok??
plus any idea on ideal pipe diameter?
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Dave A
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Registered: 10th Dec 03
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got an example of what you mean?
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SteveoBC
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Registered: 22nd Feb 07
Location: Bucks
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was thinking of renting out one of these
http://www.hss.com/g/68340/Steel-Pipe-Bender-50mm-Hydraulic.html
anygood??
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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might be, I find that my bender doesnt give great results unless you use about 3000psi of pressure, under that you tend to get a crap bend. thats based on stainless though, mild is a lot softer so it might be ok.
personally I would get the measurements and take it to your local custom exhaust place for the 2 90degree bends at the top of the hoop.
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SteveoBC
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Registered: 22nd Feb 07
Location: Bucks
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hmm cud do, powerflow are 3 doors down and across the road from my workplace
and id have to get the measurements for the bend that follows the A post and get them to do that aswell, the rest i can do with straight bars
best diameter to use??
reason im doing it this way is dont wanna spend 300 quid on a cage that is just a rollover bar and one diagonal bar on it
[Edited on 22-07-2007 by SteveoBC]
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Dave A
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1.75 or 2"
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SteveoBC
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Registered: 22nd Feb 07
Location: Bucks
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nice one cheers dave, helpful as ever
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Dave A
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Registered: 10th Dec 03
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also shop around for the tubing. you can get some that are a lot lighter but just as strong, ive seen some cages made from 1mm gauge and they are 1/3 lighter than most. needs to be a certain type of steel though, and preferably mandrel bent.
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broster
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Registered: 6th Dec 02
Location: Drives: E39
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when i had my cage made i had it made by people who knew the ins and outs properly, i wouldnt just make one myself unless i researched it properly.
a poorly desiged and constrcted cage can kill you
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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exactly why I dont do them Mark, we get a lad in that has experience of building them
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BeArDy
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Registered: 7th Aug 00
Location: Manchester
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Dave i take it yours will give pressure kinks where it has been bent?
You would have to weld the ends up and fill with sand to get a good result with that i would think.
All cages should be made out of CDS45 tubing (thats what i think its called)
I uses 52mm and 35m with a 2mm wall.
As FIA give you a spec your cage has to be to allow you to compete.
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Dave A
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Registered: 10th Dec 03
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yes adam, either fill with sand and heat up or get them mandrel bent at a local place with a nice £150K mandrel bender.
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BeArDy
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Registered: 7th Aug 00
Location: Manchester
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tell me about it, i would love a mandrel bender. I have seen on "Wrecks to Riches US" you can get a good hydraulic hand power benders to get good results in thin stuff BUT when it comes to thick stuff you into big money.
My local place will charge £10 per bend for any type of tude i give him
people who are going to make there own rollcage think to buy one is only £600 which you know is 100% stress tested and designed. You have to think is you life worth saving a few ££ ?
PLUS Rollcages should be TIG welded to make sure they are solid, where MIG'ing them i class as a suface weld and is no where near as strong.
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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tig all the way.... I dont even own a mig welder.
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BeArDy
Member
Registered: 7th Aug 00
Location: Manchester
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I will add if your planning on using the bender in the pic below, you have no chance. as all they do it snap the tubing and split it they are crap.
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BeArDy
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Registered: 7th Aug 00
Location: Manchester
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Just read your reply where you dont want to spend £300 on a rollcage.
well i would say do not even bother then.
5m for front hoop
5m for main roll over bar
4m for joining bars from front hoop to main
2m for bars for rear suspension tops
4m for the main cross.
Now this is a estimate BUT i would not think i am far off.
Total around 20m needed for a full cage
last time i looked CDS was £20 per meter
£20 x 20 = £400 for tubing
£10 per bend x 6 bends = £60
So your on £460 before you have added on welding gas, cutting discs etc etc
if your going to make a full cage for under £300 which is any use when you crash i would think again mate
Sorry but you asked my advice.....
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Dave A
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Registered: 10th Dec 03
Location: County Durham
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about right on the prices there, unless you buy tubing in bulk its not worthwhile. we buy 100m a time so we save a large amount on the materials.
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
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quote:
Originally posted by BeArDy
Just read your reply where you dont want to spend £300 on a rollcage.
well i would say do not even bother then.
5m for front hoop
5m for main roll over bar
4m for joining bars from front hoop to main
2m for bars for rear suspension tops
4m for the main cross.
Now this is a estimate BUT i would not think i am far off.
Total around 20m needed for a full cage
last time i looked CDS was £20 per meter
£20 x 20 = £400 for tubing
£10 per bend x 6 bends = £60
So your on £460 before you have added on welding gas, cutting discs etc etc
if your going to make a full cage for under £300 which is any use when you crash i would think again mate
Sorry but you asked my advice.....
no thats a fair point, this is why im asking around, i do work in a bodyshop so gas,cutting discs are'nt any concern money wise
Any ideas where i can get CDS from as if i go through my bodyshop im sure i can get a trade discount easily
what im saying is id rather spend the £400 on CDS pipe and the £60 for the bends by powerflow.whereby i get a multipoint cage which also strengthens the chassis
just seems id get more out of the multipoint £460 homemade one than a £300 hoop and 1 diagonal bar made by omp 
thoughts??
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BeArDy
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Registered: 7th Aug 00
Location: Manchester
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I can see that point yes BUT a mutipoint is not much more?
get somone with a mandrel bender to do your bends.
http://www.rollcentre.co.uk
FISA1 Front Cage £160
FISA3 Rear Cage - Fixed Diagonal £208
FISA5 Door Bar £35
Total £403 + £20 shipping = £423 to your door for a FIA Spec cage.......
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SteveoBC
Premium Member
Registered: 22nd Feb 07
Location: Bucks
User status: Offline
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quote:
Originally posted by BeArDy
I can see that point yes BUT a mutipoint is not much more?
get somone with a mandrel bender to do your bends.
http://www.rollcentre.co.uk
FISA1 Front Cage £160
FISA3 Rear Cage - Fixed Diagonal £208
FISA5 Door Bar £35
Total £403 + £20 shipping = £423 to your door for a FIA Spec cage.......
now thats the kinda thing i was looking for! cheaper than doing it myself but ful FIA spec complete cage
thats a way better option than the 300 omp one that looks a bit crap to be honest
plus id be able to weld a bar from the front cage to the front suspension turrets easily
good find beardy, defo have to save the pennies for that
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