Project Elephant - Elephant Cage

[Chuck Moreland]

This project may have fallen off the board radar for a couple months, but it has been progressing behind the scenes. My web updates are just a bit behind the build schedule. Some of you saw it at Dunkels last weekend.

True to my DIY roots, I opted to build a custom cage. I evaluated the products on the market and found some nice choices. In particular, the RS repro roll bar from TRE is nice.

But I had some very specific things I wanted that go beyond the standard produts on the market.

I didn't want a full cage. The car will be used street and track, and I don't want to be cracking my melon on a front hoop without a helmet.

I wanted Chromoly for the weight savings. Chromoly is stronger, allowing use of thinner tubing without compromising safety. The result is about 1/3 lighter than mild steel.

My goal was chassis rigidity as much as safety. That means serious triangulation and tying into the chassis at the B pillers.

I wanted removable door bars. The car will be used for street and track, and I want to pull the door bars for easy entry on the street.

I fabed all the tubing myself. I used a drill press with cross slide vice to create the fishmouths.



The fit of the joints was very good.



Chromoly requires TIG welding. Lacking a TIG, I tacked it all in place with my MIG then took it to a pro for finish welding.

I then painted to match the Gulf Blue.

Here are some pics of the results, click for more detail.





The main rollbar weighs about 25 lbs, very light. With the door bars it clocks in about 34 lbs. All in, the cage ties to 8 points on the chassis, the increased rigidity can be felt from the driver seat.

[nostatic]

a sick car gets even sicker...nice work.

[Avery]

Chuck: Very nice. When can I buy one?

BTW: My latest scans are showing that I'm beating the darn "C" thing.

Felmir

[k9handler]

34 lbs...WOW

Cut me up one and I will have it welded up once it gets here! Ha Ha

Very nice...keep the updates coming.

[Shuie]

Very nice Chuck! Excellent job.

Any plans to add the cage to the Elephant Racing catalog?

[cegerer]

beautiful workmanship.

[1974carrera]

Nice job, Chuck!! The bends in the main hoop look really good. Did you do yhe bends yourself, and how?

[rs911t]

Sweet!

[jpnovak]

Great work as always. I like the design. Can you show some side shots to show the door bars. HOw do they disconnect?

Jamie

[john70t]

Wow. Function and form. As usual, excellent craftsmanship and attention to detail. Nice job.

[ted]

Looks nice Chuck, you are a busy guy.
SOW, Big Willow, Dunkels and the next week a new roll bar.
If you need something to do this weekend join us at Buttonwillow.
John Risvold and I are doing the San Diego TT.
Good luck racing,
Mike

[bell]

it's nice to see things come together
DIY at it's finest

[Bill Verburg]

Beautiful work! Where did you tie the forward bars into the chassis? You should consider marketing that bar.

[Wil Ferch]

Chuck:
I've studied most the commercially available roll bars ( and "rear only" configurations) ...and must say you did a nice job. Some side shots/photos would be worthwhile too for us to see...
---Wil Ferch

[}{arlequin]

Chuck,

How do you connect the door bars? Does one piece go INTO the other and then the pin/bolt holds it together, or do you just use a slightly larger sleeve to mate both pieces?

[Chuck Moreland]

Mike, I won't be making buttonwillow. I need to make some setup changes based on what I learned at Willow springs.

I have no current plans to manufacture these puppies. I am reluctant to manufacture safety equipment, from a liability perspective. There is a lot of cost in it, labor wise - it wouldn't be a cheap part. And I can see that producing a repeatable part would present some challenges.

For all chassis tie points, I fabbed up plates with nuts welded to them. The plates weld to the chassis, the bar bolts to the nuts, 4 at each point. This gives the benefit of removablity, and the rigidity and safety of a welded in solution. Nothing ties to thin sheet metal like normal bolt in bars, everything is welded to the box sections.

Here is some detail on the door bars and the B pillar tie in.


Door bar slips over the spud, and bolts into place to secure the top.



Front bar bolts to plate, welded to sill. I set the foot back about 6 inches from the corner to make entry / exit a bit easier. This gives up a little on rigidity, but hey - everything is a compromise.

With the doorbar removed, the weld plate is hidden by the carpet.



Inside view.



Tie to the B pillar is key to making this rigid. I welded a plate to the pillar, then a second mating plate to the roll bar. Two bolts hold them together.

[89turbocabmike]

That is just too cool looking! Nice work...how about some door bar pics!


oops, took too long to post, you beat me to it

[dean]

Very nice job

[RSupdate]

Originally posted by Chuck Moreland
Mike, I won't be making buttonwillow. I need to make some setup changes based on what I learned at Willow springs.

Would any of those changes involve ride height....?

[Chuck Moreland]

Not to worry John, you'll get a taste of the changes soon enough