Go Back  Cobalt SS Network > General > General Cobalt
Fabricated tubular crash bar and core support build >

Fabricated tubular crash bar and core support build

General Cobalt General Cobalt, Pursuit, and Ion talk. Post specific discussions in the forums below

Fabricated tubular crash bar and core support build

Old 05-12-2019, 11:10 AM
  #1  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
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.




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




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





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




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



My work area.




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.





Bar tacked in place.




Mounting plates installed.





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



Last edited by Slowbalt2000; 05-13-2019 at 11:03 AM.
Slowbalt2000 is offline  
The following 3 users liked this post by Slowbalt2000:
jdbaugh1 (05-13-2019), steelmesh (05-14-2019), zeeky420 (05-12-2019)
Old 05-12-2019, 10:23 PM
  #2  
Senior Member
iTrader: (6)
 
Join Date: 07-19-10
Location: Denver, Colorado
Posts: 22,510
Received 381 Likes on 338 Posts
Trying to run a massive front cooler?
ECaulk is offline  
Old 05-12-2019, 10:32 PM
  #3  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
Originally Posted by ECaulk View Post
Trying to run a massive front cooler?

Mayyyyybe
Slowbalt2000 is offline  
Old 05-12-2019, 11:25 PM
  #4  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
First time notching tubes. I dont have a notcher but its actually not too hard to do with an angle grinder.





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.






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.





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.





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.






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

Last edited by Slowbalt2000; 05-13-2019 at 11:09 AM.
Slowbalt2000 is offline  
The following users liked this post:
jdbaugh1 (05-13-2019)
Old 05-13-2019, 09:05 AM
  #5  
Senior Member
iTrader: (1)
 
Join Date: 02-03-16
Location: Kansas
Posts: 4,550
Received 151 Likes on 147 Posts
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.
jdbaugh1 is offline  
Old 05-13-2019, 10:26 AM
  #6  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
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.
Slowbalt2000 is offline  
Old 05-13-2019, 11:41 AM
  #7  
Senior Member
iTrader: (1)
 
Join Date: 02-03-16
Location: Kansas
Posts: 4,550
Received 151 Likes on 147 Posts
Very nice.
jdbaugh1 is offline  
Old 05-14-2019, 11:27 AM
  #8  
Slobodan Milošević
iTrader: (8)
 
07blackg5's Avatar
 
Join Date: 11-05-07
Location: Serbia
Posts: 5,860
Received 203 Likes on 167 Posts
Looks heavy
07blackg5 is offline  
Old 05-14-2019, 11:28 AM
  #9  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
Originally Posted by 07blackg5 View Post
Looks heavy

I have the driver weight reduction mod.
Slowbalt2000 is offline  
Old 05-14-2019, 12:49 PM
  #10  
Slobodan Milošević
iTrader: (8)
 
07blackg5's Avatar
 
Join Date: 11-05-07
Location: Serbia
Posts: 5,860
Received 203 Likes on 167 Posts
Originally Posted by Slowbalt2000 View Post
I have the driver weight reduction mod.
well ****
07blackg5 is offline  
Old 05-14-2019, 01:52 PM
  #11  
Senior Member
 
Kolt's Avatar
 
Join Date: 04-19-09
Location: Jackson, TN
Posts: 3,649
Received 185 Likes on 167 Posts
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.
Kolt is offline  
Old 05-14-2019, 01:54 PM
  #12  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
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.
Slowbalt2000 is offline  
Old 05-14-2019, 02:50 PM
  #13  
Senior Member
 
ProfDNS's Avatar
 
Join Date: 01-31-16
Location: Frozen Wasteland of the North
Posts: 2,098
Received 102 Likes on 94 Posts
Originally Posted by 07blackg5 View Post
Looks heavy
Your car weight comes from the fat chicks you carry around

Nice progress Slowbalt!
ProfDNS is offline  
The following users liked this post:
Slowbalt2000 (05-14-2019)
Old 05-14-2019, 04:05 PM
  #14  
Moderator
Platinum Member
Moderator
Thread Starter
iTrader: (1)
 
Slowbalt2000's Avatar
 
Join Date: 05-15-11
Location: Livonia, MI
Posts: 24,774
Received 321 Likes on 294 Posts
Originally Posted by ProfDNS View Post
Your car weight comes from the fat chicks you carry around

Nice progress Slowbalt!

His car only has one seat, hes the fat chick.
Slowbalt2000 is offline  
The following users liked this post:
ProfDNS (05-14-2019)
Old 05-16-2019, 12:34 AM
  #15  
Senior Member
iTrader: (1)
 
Join Date: 06-07-06
Location: Minnesota
Posts: 14,116
Received 9 Likes on 8 Posts
well this will be interesting
northvibe is offline  
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
grandnational
General Cobalt
2
10-24-2012 09:58 PM
ford sucks
Suspension
3
06-20-2012 01:42 AM
csementuh
Stuff
16
10-03-2008 03:00 PM


Thread Tools
Search this Thread
Quick Reply: Fabricated tubular crash bar and core support build


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.