Rollbar Construction

Had to have a rollbar for an open Roadster, but just had to see if I could build it myself - as well as getting my money's worth out of the MIG welder.

Bought 10' of 2" x .125" tube, and had a local race-car fabricator make two 8"R.  bends to a drawing I plotted out for him.

Then I measured for the angle braces, and made the "bird's mouth" cuts using a tubing notcher I had purchased from Harbor Freight for the shop but had never used.  Boy did it work slick

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Torch cut the brackets, then cleaned them up on the mill.  Only bugger was holding everything in place while I welded.  Rear braces make a handy lift point for raising the body off the frame - just fastened a loop of chain around them, and the engine hoist could reach without contacting sheet metal.

Measurements and layout must've been pretty good - the top frames clears nicely, and the Hyundai Accent seats will fit as well ( though they're folded forward and not mounted in this pic, and probably will be replaced with another set with a touch more lateral support ).  And of course my pit crew chief, Zach, had to do the final inspection!