Custom Bolt In Roll Bar!! Plans inluded for those advancing the platform.

[bobkatkat]

Just finished a custom bolt in roll bar for the S4. Needed it for a few events that require at least a 4 point. After looking at what was available on the market and my requirements to still have a functioning back seat with OEM fold down functions, and follow the lines of the B5 S4. I decided to design my own. Here are the results. It is a bit over-designed, with 2" tubing that is a bit thicker than what is required by most regulating bodies. It has a removable harness bar and cross brace bar. The bolt in joints are milled out of solid 2" steel with 3/8 solid plate tines threaded through all tines. The floor and shock tower mounts are two sandwiched layers of 1/4 inch plate with a 1/4 inch overlap to stop scissoring. I had all the bends done on a CNC bender but could easily be bent manually.

2013 has been a great year for advancement of the platform in many respects, specifically in speed. With members like Lee and many others pushing the platform faster and faster it is time to think about the little ones we have at home. Anybody from the community interested in the CAD files for this please PM me and I will get files out to you. Drive Fast. Drive Safe.

[britishturbo]

Shit man... that's awesome!

Do want!

How much to make me one ;-)
I will probably need it very soon lol.

[Jake@JHM]

Nifty

[TheWhiteKnight]

This is outstanding! What kind of events were you running it in?

[ggg20t]

very cool sir. Have any videos/pictures from your events?

[MileMan402]

OP, all the projects your post are extremely well executed! You have some serious workmanship abilities.

Shit man... that's awesome!

Do want!

How much to make me one ;-)
I will probably need it very soon lol.

When you learn to launch with the fx700

[hots4auce]

Nice work! quick question I thought at the track they require welded cages correct me if i'm wrong.
And no i'm not talking down to anybody.

[Timtheguru]

That is amazing. :) Would love to get the specs.

[Austonwerner4]

How much does it weigh?

[wunderman4]

I would love to get the specs! I'm currently building my motor and this would really set it apart!

Sent from my XT1080 using Xparent Skyblue Tapatalk 2

[naudlee]

awesome, I'd buy one if you wanted to sell. Looks like top quality for those guys who dont want something totally permanent.

[kwazimodo]

Very very nice! Too bad it's not for an avant... Been contemplating putting one in for ages! :)

[Tec_Nine]

very cool

[ontheedge56]

Id love to take a look at the cad for this!

[bobkatkat]

Shit man... that's awesome!

Do want!

How much to make me one ;-)
I will probably need it very soon lol.

With your skills and Machinery you could do a far better execution of this design. You could definitely improve the connector design. And you already need one!! Very Very nice times.

Nice work! quick question I thought at the track they require welded cages correct me if i'm wrong.
And no i'm not talking down to anybody.

It all depends on the the track and type of racing. A lot of drag tracks require welded in. Most of the amateur, 1 mile, road course, autocross, ice, stuff i do Bolt in is fine. The biggest pain in doing the roll bars is making it fit physically and esthetically. Weather the joints are tube over slug, connector or coped welded does not really matter. Welded is by far the cheaper option.

This is outstanding! What kind of events were you running it in?

I did two cars for Speed Week at Bonneville a few weeks ago, which would have been the first use, but unfortunately it was cancelled this year due to flooding of the track and pits. Also getting ready for the upcoming ice racing series here in the far north.

very cool sir. Have any videos/pictures from your events?

No videos yet. I did fabricate 3 different style of roll bar mounts, roller boom and a crane/ jib and had plans to have cameras all over the cars but no luck with the cancellation. We usually take a few weeks and hit a few tracks along with Speed Week, but the salt flats are the big event so when that was canceled all other plans changed.

How much does it weigh?

Approximately 70-80lbs. Could be made lighter with chrome molly and smaller tubing. Also the bolt connectors are very heavy in this design. In hind sight i made them way to heavy. But I would imagine they would pass any tech inspection. I did a version for the ACR Srt-4 and it feels about 15 lbs lighter but that only uses two connectors and all other joints are welded. Having more weight in the back is never a bad thing with the b5, and the extra stiffness is incredible. O34 rear swaybar setup, batteries and meth in the trunk and 4:1 mod all add up.

OP, all the projects your post are extremely well executed! You have some serious workmanship abilities.

Thanks. I will take the complement on design but quality of execution is questionable. I am trying though.

awesome, I'd buy one if you wanted to sell. Looks like top quality for those guys who dont want something totally permanent.

I really wanted to keep the back seat usable with the ability to remove part or all of the roll bar.

Very very nice! Too bad it's not for an avant... Been contemplating putting one in for ages! :)

Everything would be identical for the avant except for the the rear supports. They would have to extend farther back. If you take a bunch of pictures and take some measurements I could make a Avant version of the Design.

To anybody that wants the plans just PM and will email them.

[kwazimodo]

Everything would be identical for the avant except for the the rear supports. They would have to extend farther back. If you take a bunch of pictures and take some measurements I could make a Avant version of the Design.

To anybody that wants the plans just PM and will email them.

That would be great. Shoot me a PM with your email and what measurements you require, and I will try taking pictures sometime next week and we could take it from there. I'm already seeing this in my car. :)

[kwazimodo]

Funny that nobody has asked this, but how much did it end up weighing?

[BITRBO]

Super clean OP - You definitely have some fabrication skills. I've been dancing around that transition from street to race car, and this is an excellent option for those that still teeder on either side. The wife will probably freak out if she sees this and the baby seat strapped down in the back seat, but obviously it's much safer!

Just a note: I doesn't look like you can lower the rear seat-backs with that cross-bar in, no?

That would be great. Shoot me a PM with your email and what measurements you require, and I will try taking pictures sometime next week and we could take it from there. I'm already seeing this in my car. :)

Diddo - I'd like the DWG files if you got 'em!

[BITRBO]

Funny that nobody has asked this, but how much did it end up weighing?

OP estimated 70-80lbs...

[Sp8t]

Wow!!!! That looks pretty legit!!! Great job!

[kwazimodo]

OP estimated 70-80lbs...

Ahh, missed that... Thnx.

[Fourplay]

That would be great. Shoot me a PM with your email and what measurements you require, and I will try taking pictures sometime next week and we could take it from there. I'm already seeing this in my car. :)

I can also assist with any Avant measurements you might need. Shoot me a PM or send a reply in this thread and I'll get back to you ASAP.

[bobkatkat]

Super clean OP - You definitely have some fabrication skills. I've been dancing around that transition from street to race car, and this is an excellent option for those that still teeder on either side. The wife will probably freak out if she sees this and the baby seat strapped down in the back seat, but obviously it's much safer!

Just a note: I doesn't look like you can lower the rear seat-backs with that cross-bar in, no?

The harness bar is the only thing that has to be removed to have the drivers side rear seat fold down. Both the harness bar and the cross brace bar have to be removed to have the pass side seat fold down. There really is not a lot of room back there but at least with how high the rear support bars are and that they run along the second half of the C pillar, access to the rear seat is not hindered.

[BITRBO]

The harness bar is the only thing that has to be removed to have the drivers side rear seat fold down. Both the harness bar and the cross brace bar have to be removed to have the pass side seat fold down. There really is not a lot of room back there but at least with how high the rear support bars are and that they run along the second half of the C pillar, access to the rear seat is not hindered.

Yeah, I wasn't concerned so much about access. I just typically lower my rear seat-backs for track events to get the CG a little lower (yes, it's miniscule, but collectively every little bit helps IMO)

[bobkatkat]

To all that have asked for the files I will get them cleaned up over the weekend in some of the file formats you have asked for. This was created in Autodesk Inventor so conversion should not be an issue. It is also setup how benders, weather CNC or manual, like to have the dimensioning ( tube Center-line, with dimensions through the bend). I did them with 6.5 inch radius bends.

For those who can help with pictures and dimensions of the Avant. Could you please take as many pics as possible. Also could you please use Isometric paper to show your measurements. I have provided a link so you can print out a few sheets. This stuff is invaluable when taking measurements in 3D space and trying to communicate those measurements to others.

1&5_Per_Inch_Isometric.pdf

[happy2B5]

Already been said but just to echo the sentiment. Awesome. Your projects do seem very well executed and super professional looking. Very nice!

[RussellR32/S4]

Already been said but just to echo the sentiment. Awesome. Your projects do seem very well executed and super professional looking. Very nice!

Yea this looks great. I'd love to have one of these in my car. I really like how functional the back seats still look for kids. You should build and sell these!

[Drehmoment]

This is a great idea for the driver with a fixed racing seat , 4 or 6 point harness and a helmet.

A bad idea for passengers or driver without the above safety equipment in a severe accident., at a minimum anybody in the vehicle would have to permanently wear a helmet just to avoid serious head injuries in a collision.

[bobkatkat]

This is a great idea for the driver with a fixed racing seat , 4 or 6 point harness and a helmet.

A bad idea for passengers or driver without the above safety equipment in a severe accident., at a minimum anybody in the vehicle would have to permanently wear a helmet just to avoid serious head injuries in a collision.

You are right and wrong at the same time. It is not a good idea to put passengers in the back seat with roll cages. It is also probably not a good idea just to have a roll cage for looks and fill your car with passengers. It is however a good idea and most of the time a must if you track, drag. autocross, fast mile etc. And at those events you would have a helmet, harness, racing seat or seat brace, fire suit etc. You also should have the roll bar padded within 12 inches of any fleshy bits. You don't need a fixed racing seat but should have a seat brace. That said as a daily driving a car with a roll cage, I have yet to see a GT3 911, gt3 r8 etc. with the driver driving around with a helmet on.

Here is two other components of my setup aside from the always present helmut. Seat brace will be permanent but 6 point only for events and the bar will be completely padded and covered in OEM roof liner fabric.

[britishturbo]

Any chance you could send me the Inventor files mate?
Cheers

[MileMan402]

I don't know much about roll cages, but shouldn't the harness mounting point be a little higher?

[bobkatkat]

I don't know much about roll cages, but shouldn't the harness mounting point be a little higher?

For my seating position it is at 8-10 degrees. That is what i wanted for me. Anybody doing one of these should set it up for themselves. Looks like i will have to create a big Disclaimer and liability waiver for those who want this.



For those who have asked for the plans I have to add in some as-built measurements and changes that evolved in the real world version. I should have that done today so i will get them out today or tomorrow.

[BITRBO]

I've been on the fence with either a cross-bar in the trunk (accessible when rear seat-backs are folded down) or one of these quick-fit setups from Schroth:



http://www.schrothracing.com/tuning/...fit/qf-vw-audi

The only problem with the above setup, is I don't think I can fold the rear seat-backs down with them installed since the hookups are basically at the stock latch recepticals... And even though it probably meets the maximum H/V angle, I prefer a more horizontal shoulder strap configuration with something like OP's roll-cage or a trunk-mounted cross bar. Eitherway, I think a simple 4-point system w/ ASM should be sufficient for HPDE.

[bobkatkat]

Any chance you could send me the Inventor files mate?
Cheers

I sent you the packed Inventor Project. Let me know you can read them.

[bobkatkat]

That is amazing. :) Would love to get the specs.

Pm me with an email.

[bobkatkat]

I have not figured out how to email members with attachments ( any ideas) so for the time being here are some images. All dimensions are in mm as requested by the CNC bender.

[bobkatkat]

Sorry for the long delay in Emailing all that have asked for the plans. Emails have been sent and i will try to accommodate requests for other file formats.

Also anybody get a chance to get some Avant measurements?

[kwazimodo]

Wont have time to do any measurements on the avany before the weekend. Would however be great if you could specify what you want measured and any reference points that can be used to make it easier for you to puzzle it together.

[bobkatkat]

Wont have time to do any measurements on the avany before the weekend. Would however be great if you could specify what you want measured and any reference points that can be used to make it easier for you to puzzle it together.

I will show you where to run a line to start taking measurements from. I will just do a photo showing the points to start from later today

[kwazimodo]

I will show you where to run a line to start taking measurements from. I will just do a photo showing the points to start from later today

Forgot all about this thread.... :S
Would be great if you could send me that photo so I can take some measurements for you!