Fabricated tubular crash bar and core support build
 

Bought myself some new toys, Woodward Fab tubing bender with 1.625" die and an AHP Alpha-Tig201xd.

https://cimg5.ibsrv.net/gimg/www.cob...5ecd0aa50.jpeg
https://cimg7.ibsrv.net/gimg/www.cob...eae8feb73.jpeg

So naturally I ordered some 4130 chromoly tubing and gave recreating the factory crash bar radius a shot.

https://cimg2.ibsrv.net/gimg/www.cob...9eadab1cc.jpeg


This is basically the third tube I ever bent so its not perfect, but itll work.


https://cimg3.ibsrv.net/gimg/www.cob...6197d0bb0.jpeg


My buddy has a 3-axis CNC so we used that to cut out the hole pattern for the crash beam.


https://cimg8.ibsrv.net/gimg/www.cob...c604283e5.jpeg

I clamped the bar onto the bumper in the place I wanted it to fit.

https://cimg0.ibsrv.net/gimg/www.cob...0443b172e.jpeg

My work area.

https://cimg9.ibsrv.net/gimg/www.cob...8d8a7a33f.jpeg


With the bar clamped to the bumper and the bumper installed on the car, I used these main bolts to hold the bar in the proper place in relation to the car. This made it so I could remove the bumper and have plenty of space to mock up the rest of the tubes. TIG welding while sitting on the floor where the radiator would normally be was definitely a chore.:lol:


https://cimg1.ibsrv.net/gimg/www.cob...51747898d.jpeg


Bar tacked in place.

https://cimg2.ibsrv.net/gimg/www.cob...4bfcb81e2.jpeg


Mounting plates installed.


https://cimg4.ibsrv.net/gimg/www.cob...23b0ca0ae.jpeg


And finally, a mock up of the design ill be using.


https://cimg7.ibsrv.net/gimg/www.cob...dcac44cc5.jpeg

Trying to run a massive front cooler?

Mayyyyybe

First time notching tubes. I dont have a notcher but its actually not too hard to do with an angle grinder.


https://cimg2.ibsrv.net/gimg/www.cob...ecd4165d5.jpeg


Drivers side tacked in place. It looks like the tack is broken because it is. I didnt like how it fit at first so I broke it off and made it fit nicer.


https://cimg8.ibsrv.net/gimg/www.cob...08448afed.jpeg



Was working until about 10:30 on a sunday just so I could finish getting the passenger side tacked in. Im pretty happy with how symmetrical it looks to the drivers side.


https://cimg1.ibsrv.net/gimg/www.cob...71ef02179.jpeg


Ill be adding one more horizontal support before I do the finish welds and give it some paint. Havent decided on the color yet. Maybe silver.


https://cimg6.ibsrv.net/gimg/www.cob...c50cbaccf.jpeg


Some shots with the bumper on to show fitment. It actually fits quite nicely and Im very happy with how it came out for my first time doing anything like this.


https://cimg1.ibsrv.net/gimg/www.cob...0edd262b3.jpeg
https://cimg5.ibsrv.net/gimg/www.cob...43de0cabe.jpeg


Might be able to finish it this weekend so I can move onto the core support. Stay tuned. :D

I assume you are just using that bolt to hold the tube in place for now? Also I'm guessing you will have everything welded to the 1/8" steel plate so it will still be removable? Interesting project, thanks a lot for sharing.

Yeah, those are actually ecotec head/main bolts. I have a whole box full of them so i figured theyd be good to use as placeholders. I tacked the bolts/bar in place with the bumper on the car so i knew it would still fit when I was done. Working on mocking up the parts with the bumper on would be pretty difficult. And yes, the 1/8” plates will be welded to the tubes and it will come off just like the factory one.

Very nice.

Looks heavy

I have the driver weight reduction mod. ;)

well shit

Looks good. Is there a reason you went with that size tubing specifically? Figured you would go with a smaller tube to keep the weight down and it also be easier to form.

I didnt know much about any of this until a few weeks ago. 1.625x.083 chromoly is commonly used for roll cages per NHRA rules. For roll bars, 1.75" tubing is required. I just wanted to have it be safe, not too concerned with weight. The car is stripped anyway.

Your car weight comes from the fat chicks you carry around :lol:

Nice progress Slowbalt!

His car only has one seat, hes the fat chick.

well this will be interesting :)