[cmartin]

I've been looking at bars for a while now. The DAS seems like a great bar will a proven record. Then I started looking at custom bars. There is a thread on rennlist now about home made bars. Being cheap, and naive I started thinking. I can weld, and have a friend that can really weld. What's stopping me from buying a cheap bender, some tubing and having at it? Basically, I could replicate the DAS bar, and make a few mods to suit my taste. I figure if follow the PCA/SCCA rules for bar standards, attachment point and so on I should be fine.

Any thoughts? Am I just crazy?

[Jim Richards]

Chris, of course you're crazy. :P

Seriously, why not? I doubt rocket science is involved. Are tubing benders expensive?

[cmartin]

This is of course a basic model, but from what I've read it's fine for the purpose and @ ~$270 it's not too salty.

http://www.jd2.com/M3B_Features.htm

I think I might be watching too much Orange County Choppers.

[BW911]

Check with Kurt, or maybe he will weigh in here. He's got a tube bender at the Taj. He and Bill Jay built a tube chasis reinforcement for Bill's 914, and it looks sweet. Kurt's the tech chief who would know what works.

Also, there's a guy around town who's known for fabbing roll bars and cages. I can't remember the name now but can get it.

Also, if you fab your own, I wouldn't necessarily copy the DAS bar. You could probably do a better one if you don't limit yourself to their bolt-in points. I have the DAS bar, and while it is a neat bolt-in solution, it can limit your seat travel. Starting from scratch with your own fabrication, and welding to the frame, you should avoid that problem.

Bill

[rs911t]

Or, I have a bolt-in Autopower bar I'm looking to sell. PM me if you're interested.

[little b]

can a bender be rented? they aren't too complicated. But that would limit your use to a certain time frame....then renting it twice makes it worth buying in the first place! rental places have all sorts of devices. but i'm sure there's a friendly dorki around with one leaning up against the garage wall 8)

[Don Wohlfarth]

How many roll bars do you intend to make? Bending tubing is fairly easy, getting it to fit is the problem. No doubt any competent welder could make a roll bar. The guys that make these for a living have an unfair advantage with their experience.
For one roll bar you may be better off having one made.

[thomschoon]

Having built a few bars and cages I would recommend having the main hoops bent by a pro with a good mandrel bender. There are tube form shops all over and they will do a good job, for little cash, if you give them clear instructions (meaning a good drawing) and can repeat it if multiples are wanted (group buy). Use the home model bender for fitting and for the small pieces.

The primary problem is getting the pieces to fit with minimum gap so you have a strong weld. Use a hole saw, plasma cutter, or a great deal of grinding and then have a certified welder finish it up. The thing is do you really want to find out the welds were cold with poor penetration while saying your prayers?

[William Miller]

cmartin:
It looks like the bug bit you like me.
I recently bought a bender and the fishmouth cutter.
Still in the box.
I hope to make some bars while I'm doing the restoration on my cab.
Cab's have to have bars to get into DE's.
I've got a few ideas like making it removable or allowing the cross bars to be removed. My kids are still small and ride in the back alot.
Another idea is to tie it into the upper seat belt sholder loop mounts wich I think might also help make the cab a little stiffer.
If your ready to start let me know you can barrow the stuff.
Mark W has my torch and I think he lives near you.
I'd like to get the specs for PCA.
I'd also like to get some plans and or measurements for other bars.

Anyone know if any of these ideas will work?

I met a guy in silver spring that built his. His fenders will be on my car soon! He made some plates with nuts nuts welded on the bottom. These are welded to a box section at the side of the rear seats. The rear angled bars have a matching plate that bolts right on , and off. I can't recall the mounting detail of the main loop.

I'll take a look at the rennlist link.

[cmartin]

Great advice guys, thanks! I realize what is meant by the slippery slope. DE so far brings enjoyment 3 fold, great people!, lot's of fun on the track and I really enjoy building/working on the car (at least when not held up on a parts order from CA). I know it makes no sense to buy a bender, but I at first thought the same thing about my welder. Not that I use it everyday, but I've made more little brackets and such than I can remember.

I'm still weighing the idea of selling what I have and getting in an already prepped track car. It's more $$ up front, but it should work out in the long run.

We'll see.