Fitting of Spyder side intrusion bars

[robertverhey]

Seeking some clear advice on the fitting of Spyder side intrusion bars which will help me and others in future.

Having laboriously prepared my wheel arches with a beautiful grey gravitex finish I now realise I'll need to cut holes in front face of rear wheel arches to feed the side intrusion bars behind the lattice work (doh!). Ah well one step forward....

Seems from previous topics that a tapering rectangular hole approx 4.5" high by 2.5" (top) and 1.5" (bottom) is required. Does it really need to be this big? Just looking at my wheel arches, this would seem to suggest that the hole should be cut fairly high in the wheel arch to clear the bonded-in vertical rod on the inside.

Can anyone verify where the hole should actually be cut and what is the minimum size hole I'll get away with? I'm determined that this will be a measure twice, cut once exercise, not the (all to common) other way around!

Photos would be particularly useful, and of course I'll add mine.

Thanks in advance

[lotocone]

Robert, I bought a used Spyder rollbar and side intrusion bars from someone who made cuts to get the intrusion bars out. He sent me the attached photo.

Anyway, I haven't done the installation yet, but the previous owner sent me this info about the holes he cut and how he would do it differently, if he had it to do over.

It is basically a rectangle that follows the inside of the fender lip and is 3" tall by 1 3/4" wide positioned 5" from the angle where the rear floor meets the inner fender. The best way to cut the hole is with a small blade on a reciprocating saw or a hacksaw blade in a handle or wrapped with some duct tape on one end if you want to saw it by hand. I just followed the edge of the hole the previous owner made when he installed the intrusion bars so it is odd shaped on my car, but had I done it originally, the hole would just have been a simple rectangle with the one side nearest the fender lip curved and following the curvature of the lip and the cut placed as close to the edge where the inner fender joins into the fender lip as possible. Keeping the hole as close to this edge allows the intrusion bar to clear the rear of the outer fender and fender flare when inserting it. The yellow outline you see in the photos is some tape that is covering the hole from the inside and the holding the piece I cut out in place.

Hope this is helpful.

[robertverhey]

Fantastic info, just what I needed. Thank you, sir.

Will post my pics when job done and dusted

[tesprit]

I am the guy that removed the side intrusion bars from my car and wrote Bob the note he posted on my observations of the hole shape and size. Here are a couple more photos of that same cut out, and the bar did slip out of that hole, but it was a tight fit.

[robertverhey]

Excellent, many thanks. Robert

[robertverhey]

The advice was good, and as per attached pics those dimensions worked (though in true lotus fashion the n/s was more problematic and the carefully measured hole needed relieving before the bar would go in)

I'm assuming the way I've got the bar protruding from the lattice front and rear is the right way? Won't know for sure until the bar is fitted.

My plan is to just loosely install the side bars into the sills during the resto. It will be concealed by the side trim. Then after car is registered and running I'll do the rest of the install (footwell bars and roll bar) This will avoid locking horns with some over-zealous engineer at the RTA during the approval process.