FFR Roll Bar Alignment Fit

[richtersand]

Hi all, sorry if this has been covered but I couldn't find anything after a few searches. My FFR roll bar is not sitting flush on both front mounts. The right front mount seats all the way down to the bead weld but the left front mount is sitting ~3/4" taller.

I have inserted the left front on it's own (rotating the hoop 180 degrees so the inside mounting point is off the car) and it fully seats. But when the two are put on together it doesn't want to seat. It appears to me to be a significant enough alignment issue that the typical sanding advice won't make enough of a difference, but I am open to any/all suggestions on this one.

https://thefactoryfiveforum.com/attachment.php?attachmentid=143191&d=1613951733

https://thefactoryfiveforum.com/attachment.php?attachmentid=143189&d=1613951701

[Jeff Kleiner]

How is the fit of the rear leg?

Jeff

[richtersand]

How is the fit of the rear leg?

Jeff

Hey Jeff, thanks for the quick response. You're always so helpful on the forum, really appreciate it.

As far as I can tell, the rear leg is good. Seats well and inserts into the post on the hoop snug but not too tight.

[Railroad]

I had to put a ratchet strap around the legs and pull them closer together for the complete roll bar to align with the post.
If the hoop legs are too far apart to fall down freely this might be your problem. Good luck.

[Rdone585]

If the two legs need to be spread (as opposed to pulled in like Railroad did), cut a 2x4 about 1/8" longer than the gap between the two. You can then use it to pry the two legs apart by a little TLC hammering. You can get this 2x4 to work better if you drill 2 holes the right distance apart in the 2x4, then cut through the center of the holes. The holes will keep the 2x4 from sliding off while you hammer. You can also drill one of the holes at a very slight angle so the 2x4 wedge you just made fits better at the starting point. This technique has worked for me in many different circumstances. I hope I've explained it well enough to understand.

[egchewy79]

I think Jeff meant how's the rear leg fit relative to the hoop.

[richtersand]

I think Jeff meant how's the rear leg fit relative to the hoop.

I think it’s good. I don’t think it will be fully seated but it’s workable slightly elevated. Maybe that’s not right though? I’m not sure. Thanks all!

[CraigS]

A soft 2x4 and a sledge hammer may fix that.

[Jeff Kleiner]

I asked about the rear leg because if the hoop isn't in the proper position you'll have a bear of a time getting it to engage at the top.

Measure straight down from the top of the hoop to the trunk floor with the rear leg engaged top and bottom. I just checked 2 of them and both measure 24 5/8" + or - 1/8". If that's what you get consider the possibility that the outside end was cut short; if yours is much more than that it may be that the inner end is long...but I'd expect that to make it very difficult to engage and fully seat the rear leg.

Let us know!

Jeff

[Ernie67]

The mark in the paint looks like there might be a burr on the inside of the tube. I'd check the other tubes as well, collectively the removed burrs may get you where you want to be. A little may give you a lot.

[richtersand]

The mark in the paint looks like there might be a burr on the inside of the tube. I'd check the other tubes as well, collectively the removed burrs may get you where you want to be. A little may give you a lot.

If I rotate it so only the left side is inserted it seats easily, so not a burr inside.

I tried the ratchet strap last night with no luck. Will keep you all posted.