A few weeks ago we had one of our long time customers, and TF sponsored drivers, Devin Giles drop off his boosted S2000 time attack car to have his current roll bar modified into a full fledged roll cage fabricated for his car. The previous roll bar had been in the car for a couple of years and needed to be slightly modified for more reinforcement and structural integrity. When the car first got here, I myself was out of town so I didn’t get a chance to document the process of the old roll bar having its two rear supports cut out, the minimal interior being pulled out and a few initial measurements. But! The majority of the process was photographed so let’s jump right into it:
We added rear plates to reinforce the floor where the supporting bars would meet the chassis.
The top of that same support bar! Tacked onto the main hoop.
Our fabricator Steve loves flames and sparks. Here he is grinding down the opposite support bar for a precise fit with the main hoop and cross bar.
Boom! The other support bar is tacked onto the other reinforcement plate that we welded on earlier.
You can see the remnants of the old support bars that were on the main hoop.
Everything is mocked up; the rear cross bar hasn’t been tacked on yet, not until a few more adjustments are made so the fitment is perfect.
To get started on the driver and passenger hoops, floor boxes had to be made. We wanted to make floor boxes that wouldn’t cut down on the already tight for space S2000 interior, but wouldn’t sacrifice safety or strength. Steve came up with the cow floor boxes!
Here’s the origami version used as a mock up for the final metal pieces. It sits more on the frame than the thin floor, gives plenty of area for the bar to be welded on the top, and looks cool!
Here’s what the finished product look like after a few runs in the bending machine.
Cleaning it up just a bit from the plasma cutter.
How it sits in the car.
A little more cleaning up…
And it’s in the car!
We made some seat brackets as well for the Sparco Circuit II seat.
The seat installed in the car.
Bending some test piping for the main driver and passenger side hoops!
Piecing it all together.
Here’s the driver side floor box completely welded onto the chassis!
Cutting into more piping!
Spot on fit.
These will be the strut tower support bars that will branch off of the driver and passenger door hoops!
Fitting up the bar before adding a reinforcement plate and finalizing placement!
Windshield bar tacked onto the door hoop on the driver’s side…
… and the passenger side!
This is the path the strut tower support bars will go through from inside the cabin to the engine bay.
Time to make gussets for the windshield support!
Drilling out the holes to size.
Dimple die all the things!
Here’s how the center gusset plate looks being held on by a magnet.
Driver side gusset tacked on!
And the passenger side.
Welding on the rear support bars.
Cut cut cut!
You can see the chassis reinforcement plate here that was welded on before the bars were installed.
Steve welding up the rear support bars.
Passenger side gussets.
Top plate welded in, the windshield is ready to go back on!
The door bar mock up bar.
We had to remove some of the door guts to add the door bars.
Bar 1 is done!
Bottom door bar on!
Welding on the supports between the bars.
Fuel door release!
Passenger door bar detail.
With the passenger door bar on, the cage is finished!
Thanks for checking out the cage build on the TF Blog! Check back for product reviews, releases and our soon to be introduced wheel sizing and seat sizing reviews!