Safety Devices Rollbar and side impact bars

[Chris-72-Sprint]

Does anyone have any pictures of installing the rollbar and side impact bars

I had a quick look at mine today (body already off chassis) but it looks to me like the side impact bars and going to foul on the sill reinforcement rod by the rear wheelarch. Also interested in the floor/chassis mounting points

Any help much appreciated

Chris

[bill308]

Chris,

I don't have any photos at this time but side impact tubes are longer then necessary and must be cut to the proper length.

Bill

[Old English White]

Does anyone have any pictures of installing the rollbar and side impact bars

I had a quick look at mine today (body already off chassis) but it looks to me like the side impact bars and going to foul on the sill reinforcement rod by the rear wheelarch. Also interested in the floor/chassis mounting points

Any help much appreciated

Chris

First of all , Chris ,
FHC or DHC !?!
The Safety Devices rollbar must be fitted bodyshell on the chassis .Then , because the fitting kit is with metric , you will have to go through the aluminium bobins of the body (I personnaly found this hard to believe).
If in a Coup? , you may have some difficulties ... But it is not necessary to remove a door . The Steering wheel , seats , central console , and the gear lever only ... The trick is to put it "legs up" in the car , then have it turn inside ...
The side bars need to be cut (because they could be use on +2's).
At last , the last difficulty should be the rear fixation , the bars need sometimes to be banded with ropes and the long bolts going through the bar , the plate , the body and finally the chassis could be hard time .
Hope this will help, but sorry , no pictures of that moments!
Christian.

[Chris-72-Sprint]

Thanks for the replies which have helped

Just so I have it clear

1. The floor mounts for the rollbar and the front brace on the side impact bar are fixed using the same holes as used to bolt the chassis to the body...but these are drilled out to allow the metric nut and bolts in the kit to be used.

2. I understand about shortening the side bars and it may be clearer when I do the job (after the body is painted) but it looks to me like one of the thin sill diagonal bracing rod is going to be in the way where the side impact bar turns in to join the rollcage.

I guess my question is does the side impact bar go infront of the sill bracing rod or behind it ?

3. The car is an FHC so understand about lining up rear mounts


Thanks for all your help

Chris

[ElanSeries2]

Hi Chris

I'm just about to install one into my S2, so obviously I won't have the same in-car Rubiks Cube to solve, but the side bars will be the same. I've not yet summoned up the courage to cut the back out of the sill, but that is the next job. Getting the roll hoop in was very easy - all the holes line up no problem. I'm not sure about the front bars - I can't yet see whether there is a chassis mount there. I'll PM you...

Greg

[Chris-72-Sprint]

Thanks Greg

I have cut the wheelarch holes which wasn't too bad.

Now I know that the rollcage bolts through the bobbin holes I will have another look one night this week to see if I can work out if the sill bracing rod is in the way of the side impact bar.

I will post some pics when I get that far

cheers
Chris

[SADLOTUS]

Hi Chris

Found these pics, taken during rebuild. Not as comprehensive as you may have liked but hopefully others may add to them.
I had to very slightly bend the sill reinforcement rod to fit the roll bar.
Paul matty suggested fitting studs into the rear suspension strut uprights then bolting the rollbar angled down tubes to the studs. I found this easier than trying to bolt the bar in. Also had to use a spacer on the stud to clear the hood tray and 'stand' the cage upright enough to sit square to the floor.
All nuts and bolts are finger tight until the end.
The side bars went in three or four times - cutting a little off the end each time.
Also watch the seat belt anchorage points in the centre backbone - It's a tight fit and you may want to do that before fitting the cage.
BTW, I fitted the cage before cutting the rear wings off...Doh

Paul

[garyeanderson]

The following three photos are in the Technical Tips section under

http://www.lotuselan.net/publish/safety ... lbar.shtml

[Chris-72-Sprint]

Thanks Paul - thats the picture I needed to see. The sill bar goes in front of the sill brace rod. I think mine will need a slight adjustment also.

regards
Chris

[kenb]

Hi,
Cutting into the rear wheel arch was no big deal,top roll cage bolts into rear suspension tower was a bit of a sweat.
NB: there is a new FIA approved seat belt harness bracket which has long bolts which have to be bolted on the "blind end"after drilling the threaded part of the tower.TTR has the bits.
My cage ex Bean didn't come with instructions so I found that Safety devices get them from TTR anyway!Or at least use their jigs!
Sorry no pics as I am in the Isle of Man (TT Races.
Ken B
Canada

[patrics]

Hi Chris

If its not two late I would fit the side bars before its painted as they rub against the rear arch when fitting.
You also have to mess about to get the length right - it's not easy to judge how much to take off.

Regards
Steve

[Chris-72-Sprint]

Hi Steve,

I was just thinking the same thing having spent an hour in the garage tonight

The body is sitting on horses and 4 x 4 crossposts at present.

I have temporarily located the rollcage to the body and then cut small amounts off the sill bars each end to get the right fit. The left side is almost finished.

My plan is to complete both sides and then either:-

1) make up plates to fill the rear wheelarch holes, underseal the arches and then ship the body to the paint shop.

or

2) do as above plus paintwork in the engine bay and then put body back on repainted chassis/refurbished suspension, fit rollcage/sill bars and then ship off to paint shop.

I dont really like option 2 because the body needs lots of prep work and I fear crap/overspray on chassis/suspension

All advice gratefully received

thanks
Chris

[patrics]

Chris

My S4 is away at the moment to be sprayed, I left the side bars in but nothing else. I made up a wooden trolley with wheels for it to sit on.

To fill the holes I just bonded in the cut out bits and matted over to finish.

The arches and engine bay can be painted / whatever later.

Cheers
Steve

[Chris-72-Sprint]

Hi Steve,

thanks for info - I prefer that route - out of interest how did you get the body to the paint shop ?

Unfortunately I wasn't sensible enough to keep the bits I cut out the rear arches so I will probably make up some ally plates and pop rivet/mastic

regards
Chris

[patrics]

In a Merc Sprinter van but the doors wouldn?t close with about 3 inches sticking out ? should easily fit in a long wheel base one.

An easy way to fill the holes is just to bond up three or four layers of matting off the car, when its gone off shape to suit, bond in with p40 type stuff and tissue over.

Cheers
Steve