boxing a frame and adding a cage for added strength

[grumpyvette]

once your car exceeds about 400 hp the stock frame and suspension stress levels start to increase enough that you may need to compensate with a more rigid frame and suspension mods. many older cars had frames welded from C channel steel that was quite flexible if not braced properly and many newer cars have only front and rear suspension mount,sub frame assembly's bolted to a sheet metal body that has little structural strength compared to a full frame design

TWO very good reasons to select a decent T.I.G. welder for your shop over a similar M.I.G. welder is the fact that ROLL CAGES MUST BE TIG WELDED and ALUMINUM is BEST WELDED with a TIG WELDER.

ALL THESE LINKS CONTAIN USEFUL INFO

viewtopic.php?f=60&t=870&p=1358&hilit=+roll+cage#p1358

http://www.rodandcustommagazine.com/tec ... index.html

http://www.progressiveautomotive.com/Boxing.htm

http://theoldcar.blogspot.com/2010/01/frame-boxing.html

http://www.millerwelds.com/resources/ar ... cle96.html

http://www.youtube.com/watch?v=1ZQdCxke ... re=related

http://www.youtube.com/watch?v=6St6SXgB ... re=related

viewtopic.php?f=61&t=3426&p=9080&hilit=roll+cage#p9080

viewtopic.php?f=87&t=1187&p=2442&hilit=+roll+cage#p2442

 

[grumpyvette]

here a few tools many of us just wish we had and a few of the more affordable tools
keep in mind most tracks require tig welded chrome moly steel ROLL cages and have very detailed rules about the number, of braces,tubing size ,wall thickness and placement of the loops and bars,braces and gussets and floor plates to be used
The reason many people who do their own cages use mild steel is because they can weld it with a mig welder. You have to weld chrome-moly with a tig welder and you have to be a decent skilled welder too so, many DIY guys don't all have the tig welder required for chrome-moly. If you're paying to have the work done in mild steel will be cheaper than chrome-moly . There is 2 types mild steel tubing used ERW and DOM. ERW is a cheaper tube and will usually have a .134 wall and DOM costs more but would have a .120 wall so it's lighter. The chrome-moly will have a .083 wall and will be the lightest but cost the most. They're all safe if correctly braced and weld and which one is best would depend on how much you have to spend and how fast you want to go. If you plan to go faster than 7.50 you'll have to use moly since MS will only pass a 7.50 certification.


viewtopic.php?f=61&t=3426&p=9080&hilit=roll+cage#p9080

http://www.pro-tools.com/302.htm

http://www.cachassisworks.com/c-165-sid ... -sets.aspx

http://www.pro-tools.com/200.htm

http://www.harborfreight.com/16-ton-hyd ... 35336.html

http://www.ercolina-usa.com/tb80-tb100-top-bender.htm

http://www.youtube.com/watch?v=9au7P7_N ... dded#at=90

http://www.northerntool.com/shop/tools/ ... _200003774

viewtopic.php?f=44&t=1518&p=3473#p3473





12 ton
http://www.harborfreight.com/12-ton-hyd ... 32888.html

16 ton
http://www.harborfreight.com/16-ton-hyd ... 35336.html

Ive used both friends have purchased the 16 ton rated ones SLIGHTLY easier to work with building roll cages, both are bottom line quality but far far less expensive than a professional shops pipe bender



http://www.grainger.com/Grainger/WESTWA ... 7QodvSrr6A

http://www.pro-tools.com/302.htm

http://www.vansantent.com/tube_bending_ ... chines.htm

 

[Indycars]

I wouldn't mind taking one of Ron's classes for metal shaping. The price is not too bad I thought at $1000 for 3 days and they supply all your metal. Class size is only 6 students max.

http://www.fournierenterprises.com/About%20FENT.html

About Ron Fournier
His career began with Holman and Moody in 1964, and since that time racing greats such as Roger Penske, A.J. Foyt, Kar Kraft and Bob Sharp Racing have all utilized Ron's unique skills to transform metal into various components for their championship-winning race cars. General Motors, Ford and Chrysler have also contracted for his fabrication and training services.

In the 1970s, Ron founded Race Craft, which developed a reputation as one of the finest metal fabrication shops in the U.S. Ron and his wife, Sue, have written two books now considered essential references in the automotive metal work field: Metal Fabricator's Handbook and Sheet Metal Handbook. In 1984 Metal Fabricator's Handbook received a Moto Award, the highest achievement in automotive journalism.