Teddy-2000RS

Scored a new welding table from my schools scrap metal bin. Going to add legs and casters so I can roll the bender around as well.



Then took a step backward



And then took two steps forward





With a little bit of fine tuning I managed a clean 60° notch out of my notcher.

67Lark

So why did you go as far as adding that bar? That seems to be quite overkill. I've seen lots of cages and many with vertical bars right up the middle but never one off to the side like that.

Teddy-2000RS

I'll be adding this top bar as well. Its what the fia approved stage rally cars use.

67Lark

Oh ok that makes more sense. I've seen those but I've never seen them broken up like you have it. But being in a small chassis like a subie you don't have the space like fullsize cars do

DW SD

I hope you have a good helmet for street use!
All that tubing around my (dome / cabeza / melon / skull / head) would make me nervous.
Or is this a track-only car?

Did you use FEA to design the cage? Or are you copying a design from a similar (rally) car?

Doug

AussieDan

Looking at that bar compared to the pic, you have the notch on the opposite side tying it into the X instead of the upright. I'd have thought tying it into the upright would make more sense?

67Lark

To keep the pipe going straight and still allowing him to get in the car it would have to be notched tie into the x vs the upright

AussieDan

Not sure I follow, the tube would remain in almost the same position. If you look at the example photo you can see that the notch is on the opposite side so that it's welded directly to the main a-pillar tube just above above the lower arm of the X rather than being welded to the X.

67Lark

However the example picture is on a larger chassis car which has the a-pillar tubes at a different angle which allows that bar to be done in one piece. It also allows that bar to be done at a different angle allowing the driver to still be able to get into the car.

Moving the bottom of that bar 3/4" and keeping the bar straight would effectively move the top of the bar backwards 2 inches or so which would block more of the entry into the car. At least that is my thought process on it.

Teddy-2000RS

This will be a full on street car. I plan to take it to the strip and a few 1/2 mile shootouts, but just for fun to see what the car is actually capable of. I'm 6'1 so my seat will be damn near sitting on the floor pan with my head away from the majority of the tubes for when im on the street and I'll be employing a helmet whenever I really want to let it out of the barn.

I pull inspiration from any "safe" cage I can find, but the majority of my ideas derive from FIA stage rally cars and short course trophy trucks.

I tied the bottom to the X in hopes of keeping added stress away from the a pillar tube. In the event of a rollover the top will support the a pillar and the bottom will be supported by the X. It's all theory as I do it so keep the suggestions/ constructive criticism coming!

Took a small break from my car to scoop some extra cash. Started with a gauge install on my roommates MK6.



Then rescued a captured nut from a turbo honda's subframe



And attempted to start back on my cage when the saddle of my notcher decided it was no longer attached.



Welded it back up



And finished the bar I was working on



Next up is the remaining upper FIA bars and then stage 2 of welding begins.

Teddy-2000RS

The upper FIA bar is proving to be slightly tricky. It requires an 80°ish notch and my notcher's limit is 60°. After messing with multiple cardboard templates and even a toilet paper roll, all to no avail, I searched around online and found a notching template program. I printed out the templates and traced the pattern onto a test tube. A little bit of elbow grease with an angle grinder and it works.





I'll try it out for real tomorrow.

Teddy-2000RS

The templates proved to be a great success.



Hand notched perfection





All fit up





Had to notch around the intersecting roof bars





Now time to decide on a dash beam/bar.

Narxoleptic

Can we rename this to Jungle Gym?

Project GatTagO

iTrader: (7)

You said Jungle Jim....I thought Pam...



LOL

Andrew

Teddy-2000RS

I've been practicing getting in and out of it at the local park.

Teddy-2000RS

Pulled it outside and ground the tacks down. Should be ready to start welding the door portions tomorrow.

Teddy-2000RS

Got a bit of welding done today. No crazy upside positions today so that was nice.






And my favorite weld if the day

Narxoleptic

weld looks great! Put a glove on.... i dont know how you are going to get in and out of this thing with those bars but post videos for sure when you're done, lol. #junglegymandpam

Teddy-2000RS

Ive got one on! I'm deciding on a new pair, my good pair are pretty haggard from use.

Didn't get nearly as much done as I would have liked but my welds are getting more consistent by the pass.

Teddy-2000RS

Got a bunch done today before running out of shielding gas. I fly out to NH for my short "summer break" tomorrow, so in two weeks I'll be back to finish it up.

In the mean time here's some prettier welds of the day.










And just because I like to look at it