Time for a Roll Bar

[johber41]

I am going to use the bad weather to go ahead and finally install a roll bar. I know that the wife and daughters think it is a good idea. Found a decent home-made roll bar on the Samba which was assembled by a guy in College Station that knows a lot of you guys in the club.

[BrianB]

Looks like a good start. Single Hoop or are you going to add other bracing? Single is really just considered a "Show Bar" Keep us posted.

[johber41]

Thanks Brian, I had to fabricate mounts that matched the rounded edge of the rear pan. They turned out better than I expected just a lot of cutting and MIG welding, grinding. I was also lucky I found an old metal support from a hide-a-bed that I was saving. It will be the perfect tie-in to the windshield after some more cutting and welding.

pics attached

[Aquabuggy]

Lookin good !! Keep progress pics coming.

[Bill K]

Chris, it's great to see you again on the Forum. How's the Buggy?

[johber41]

Got the fabrication done and I am a little disappointed with the thickness of the bed-frame part I used to tie the roll bar to the windshield. I may copy that later in a heavier metal. Now I need to tear it down, paint it , and re-assemble it and I may tack weld the mounts to the pan even though the bolts are giving it plenty of strength. I need to add some plate steel to the bolts underneath the car for some added strength. The roll bar that I am using was designed for rail with bolt-up or weldable connectors fabricated on the back of the bar to receive two down supports. I was going to grind the connectors off, but instead, I might throw some extra stop lights in them. The windshield mount was an easy build, cut from some 4 " rectangular tub steel and pinched in the front so that the windshield can receive it like my convertible top.

pics added

[Aquabuggy]

I think its a good idea to keep the connectors, ya may want to add the down tubes at some point.

Hey Bill, The buggies are still just collecting dust sitting in the shop. I think we should be in our new house maybe March so hopefully ill be back to bugging in April

[johber41]

I thought of that Chris, but I have so much going on behind my seats. I have a harbor freight trailer tongue tool box for a trunk and its a place for my convertible top to fold onto and to be snapped down. I have the down tubes, but they are bigger than I would have made them. I understand that the builder intended the setup for a sand rail, not a manx style buggy. The whole set is made of very heavy steel, at least schedule 40. The hoop however is working out for very well for my car with my top folding over and clearing the whole configuration.

[johber41]

Done...for now!

[Ken]

Looks great from here John. Look forward to seeing it up close.

Hi Chris, man it seems like its been a really long time. Hope y'all can make a gathering this year. I would be great see the growing family.

[johber41]

Thanks Ken...hope to see you guys soon.

[Joe]

It is looking good. Did you make your top for buggy?
Joe

[johber41]

No, the top is from 1966, I just put a lot of product on it. I really need to get a new one made, but this one will work until I can get the right deal. I have the inside of it reinforced with gorilla glue and tape where it is the weakest.

[johber41]

I wired up the roll bar to use the down-tube connectors as turn signals and brake lights. turned out to look pretty nice and it gives me more visibility with other drivers.

[ScottR]

Looks great. How did you find the lights so fast...and they look like they fit like a glove.

[johber41]

I had them in my parts storage...I purchased them on-line for an old 1965 honda s90 motorcycle I rebuilt and they were 6v. They did not fit the application for the bike so I just held on to them. They are LED and they were just shy of fitting into the connectors so I shoved them into a piece of handlebar rubber and they push in nice and snug. Really got lucky I had the parts and that they fit like that. Thanks Scott!

[Bill K]

Looks like they were made to order. Great job.

[johber41]

Thanks Bill