[Land-speed] rollcage welding

[Joe Timney]

Benn,
It is not necessary to weld it all the way around the tube but you will 
need to gusset it. You can get about all but a 1/2 to 3/4 of an inch if 
you leave a 1/2 inch of side clearance by 'Hanging out' the tungsten 
from the cup. This type of thing happens all the time in chassis 
construction.
joe

Benn wrote:
> Thanks for the response, Dave.
> I don't think it'll be possible to get more than the main bar with 
> some sleeve stubs removed from the car temporarily--any significant 
> extensions just won't have enough room to maneuver.
>
> I do kinda like the "slide it forward" approach:   But I'm trying to 
> get the main hoop as tall as possible, and that means it fits behind 
> the roof reinforcement at the rear of the T-tops.  I also only can 
> move it forward about 4" (need up to 8" to get the main hoop into the 
> door opening) without moving the front hoop closer to the main hoop, 
> since the front hoop will othewise run into the A-pillar.
>
> Hmm, maybe the main hoop could be pivoted about its top without the 
> front hoop attached.   Some puzzle-fitting may work by moving some bar 
> positions a few inches...  Thanks for the thoughts--I may need to use 
> some combination of all these approaches.
>
> So is the implication that I'd need at least "several" inches 
> clearance to a wall to get a good weld around the circumference of the 
> side bars?
> Benn
>
>
> ----- Original Message ----- From: "Dave Dahlgren" <ddahlgren at snet.net>
> To: "Benn" <karhu at california.com>; <land-speed at autox.team.net>
> Sent: Thursday, February 26, 2009 10:22 AM
> Subject: Re: [Land-speed] rollcage welding
>
>
>> Couldn't you tack everything to the main hoop but don't permanantly 
>> mount it in the car. Pop it out  or slide it forward do the outside 
>> welds then drop it back in or slide it back with the door bars 
>> attached to the hoop?
>> ----- Original Message ----- From: "Benn" <karhu at california.com>
>> To: <land-speed at autox.team.net>
>> Sent: Thursday, February 26, 2009 12:28 PM
>> Subject: [Land-speed] rollcage welding
>>
>>
>>> Planning the rollcage for the MR2, and want to plant the main hoop 
>>> as far
>>> outboard as possible.  BUT, since it's behind the door opening, 
>>> there is no
>>> way to weld the horizontal side (door) bars fully to the main hoop 
>>> if it is
>>> hard against the interior body panel.  So, the question is, what is the
>>> minimum clearance I can get away with and allow a good welder (not 
>>> me) to
>>> still be able to weld the bars around their full circumference?  A 
>>> half inch?
>>> full inch?
>>> Benn
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