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Old 12-26-2011, 08:02 PM   #1
TerryH
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Default Roll Cage is underway..........

OK, I give. I really didn't think that I wanted to put a cage on my cart but I do want to have some good seat belts and I want a windshield that is laid back much more that the regular sport windshield so it seems logical that the best way to accomplish those things is to build a cage.

I took the cart over to Bob's shop this morning and we spent the morning measuring and brain storming.

My criteria for the cage:

1. It must have an integral windshield frame that is much more laid back than what I have now.

2. It must provide a place to mount 2 good 4 point harnesses.

3. It must be a design that functions well but still goes with and looks like it belongs on a lowered street cart not on a off road cart.

I began researching several days ago by searching on the net for anything to do with race car chassis or roll cages in general. I really did not see anything on a regular golf cart that I thought would fit the bill. I discovered that the cages that I liked and looked to me like what would fit my criteria were the upper section of the chassis on sand rails. Something like this...



The first difference in this style of cage and the way that most golf cart cages that I've seen is the it uses a windshield hoop and a main hoop instead of the 2 solid sides. The hoop design allows the upper connecting tubes to be moved inboard so the head clearance for getting in and out of the cart is greatly improved without the cage being as tall as they normally are. The connecting tubes will also be arched above the driver's and passenger's heads to allow for more head clearance.

This design will also allow me to actually mount the windshield on tabs inside of the hoop instead of on top of the bars like the sport windshield is so it will have much more of an automotive/race car look to it. There will also be 2 rear tubes going from the top of the main hoop to the back of the bag well. They will be bolted to the rear crossmember. The main hoop will mount the belts and the seat backs. I have always wanted the seat backs to be back farther than the supports that I have now so this will give me the chance to put the seat back where I want.

I ordered belts from Crow Safety because they had purple. They are 3" wide - 4 point belts like these but purple of course. They are in the UTV / Sand rail section of the Crow website. $79 each.



Here is a shot of a sand rail with the type of upper cage that we are building. You can see how the inboard upper tubes will allow for the hoops to be shorter but still have head clearance.



The cage will be all 1.5" tubing with .120 wall. If you remember, I bought a donor cart that I robbed the rear end out of and rebuilt so I hauled that cart over this afternoon and left it at Bob's shop so he can fit the cage to that one and not endanager the paint on the real cart.

I'll post more when the work actually begins.
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Old 12-26-2011, 09:48 PM   #2
eaglesdad1
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Default Re: Roll Cage is underway..........

After seeing some of the things you and Bob have come up with I am sure it's going to look very cool !!!! Can't wait to see it !
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Old 12-26-2011, 10:42 PM   #3
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Default Re: Roll Cage is underway..........

Hurry upppppppppppp. I need more pictures
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Old 12-26-2011, 11:19 PM   #4
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Default Re: Roll Cage is underway..........

Oh I can't wait to see this. I started to use .120 wall but the guys at stock car steel talked me out of it. I ended up using .083 wall. But I can't remember what type of tubing it was. They told me the only real difference between DOM and what I used was that you don't see the seam in DOM. The biggest thing those guy stressed is that it don't matter what tubing you use if its not designed and assembled correctly. I got to talk with some chassis builders about cages. They told me that there is no one correct way to build a cage but a million wrong ways. I have two more carts lined up for cages. I love building them for each one being unique to what the owner wants. Have fun with it Terry and I look forward to many pics. I'm sure you will do a outstanding job. What color will it be?
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Old 12-27-2011, 07:36 AM   #5
TerryH
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Default Re: Roll Cage is underway..........

Quote:
Originally Posted by blake80 View Post
Oh I can't wait to see this. I started to use .120 wall but the guys at stock car steel talked me out of it. I ended up using .083 wall. But I can't remember what type of tubing it was. They told me the only real difference between DOM and what I used was that you don't see the seam in DOM. The biggest thing those guy stressed is that it don't matter what tubing you use if its not designed and assembled correctly. I got to talk with some chassis builders about cages. They told me that there is no one correct way to build a cage but a million wrong ways. I have two more carts lined up for cages. I love building them for each one being unique to what the owner wants. Have fun with it Terry and I look forward to many pics. I'm sure you will do a outstanding job. What color will it be?
Bob is going to go to the supplier that he gets pipe from and check out some thinner wall tubing this week. I'm not sure which we will use. I'll leave that up to him. He has built many cages and complete chassis so I'll go with whatever he thinks is best.

I'll paint it purple to match the cart. Couldn't imagine that I'd be happy with it any other color.
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Old 12-27-2011, 08:03 AM   #6
blake80
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Default Re: Roll Cage is underway..........

Quote:
Originally Posted by TerryH View Post
Bob is going to go to the supplier that he gets pipe from and check out some thinner wall tubing this week. I'm not sure which we will use. I'll leave that up to him. He has built many cages and complete chassis so I'll go with whatever he thinks is best.

I'll paint it purple to match the cart. Couldn't imagine that I'd be happy with it any other color.
like i said, i started using .120 wall DOM and man that stuff is thick. after working with some of it, its easy to see just why pro motor sports drivers can walk away from a crash most of the time. but, with the little bit of tubing he will be using, weight will not be a issue. i know my whole cage without seats only weighs about 60lbs. but, i will tell you this. it is going to change the way your cart rides. most people dont realize how much the frame acts as part of the suspension. it really firms the cart up. which ever tubing BOB THE BUILDER ( i had too) goes with, you will love the cage. it just being on the cart, it gives you a better feeling of being safe.
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Old 12-27-2011, 08:09 AM   #7
TerryH
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Default Re: Roll Cage is underway..........

[QUOTE=blake80;665737] which ever tubing BOB THE BUILDER ( i had too) goes with, you will love the cage. QUOTE]

Haaaaaaaaaaaa!!!!!!!!!! He is Bob the builder.
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Old 12-27-2011, 08:11 AM   #8
blake80
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Default Re: Roll Cage is underway..........

[quote=TerryH;665738]
Quote:
Originally Posted by blake80 View Post
which ever tubing BOB THE BUILDER ( i had too) goes with, you will love the cage. QUOTE]

Haaaaaaaaaaaa!!!!!!!!!! He is Bob the builder.
i bet that would be the first time he ever heard that
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Old 12-27-2011, 08:24 AM   #9
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Default Re: Roll Cage is underway..........

Quote:
Originally Posted by TerryH View Post

Haaaaaaaaaaaa!!!!!!!!!! He is Bob the builder.


Just had tooo,,,,sorry Bob!

http://www.bobthebuilder.com/usa/index.asp?origref=
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Old 12-27-2011, 09:52 AM   #10
Flintrock
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Default Re: Roll Cage is underway..........

I think you should wrap it in diamond plate.......
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