Roll Bars

Now if this is the job that every­one is nervous to under­take, I can tell you that I was ter­ri­fied .….….……as I had the body painted with a cus­tom paint­job pri­or to tak­ing receipt – the drilling and fit­ting of the roll bars.

This job can­not be under­taken until the body is moun­ted to the chassis, align­ment with the mount­ing points is then required which requires care­ful plan­ning, meas­ur­ing and meas­ur­ing again.  The mount­ing points con­sist of 2x hard points on the chassis and the third is fab­ric­ated by cut­ting a rect­an­gu­lar hole and mount­ing a brack­et (avail­able from GD) in con­junc­tion with the shock absorber.

Firstly, a centre line was estab­lished using a self lev­el­ling laser in both the hori­zont­al and ver­tic­al planes which, to be can­did, was bril­liant.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Mul­tiple iter­a­tions of meas­ure­ment sub­sequently ensued and pilot holes drilled upwards from the under­side and then suit­ably opened using a 90º drill head and holesaw.

This allowed the laser line to be relo­cated over the centre of the hole and using the ver­tic­al plane, a dot was pro­jec­ted to the under­side of the body mark­ing the centre point, this was drilled with the Dremel and using a trusty needle and cot­ton as a make­shift plumb-bob val­id­ated, as being “true”

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Hav­ing done this for each pilot hole there were no adjust­ments to make and so it was simply a case of drilling with the hole saw, slightly over­sized to accom­mod­ate the body grom­met (4@ 60mm (front) and 2@ 51mm (rear)).

 

 

 

 

 

 

 

 

 

 

Some fet­tling is required to slightly widen the holes in the boot to accom­mod­ate the legs more snug­gly, which can then be sealed.

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