Passenger Roll Bar

[Hoodlum60]

Has anyone added a passenger side roll bar after the car was painted and finished. I was thinking about it on my car, but drilling those big holes in my nice paint scares the crap out of me. I hear the holes were pre-marked on the unfinished body. Are there templates for this?

[j.miller]

Three ways to do it. A. Find a car near you and ask the owner if you can make a template. 2. Start with a small tube inside the rollbar bung , mark the bottom, drill up with 1/2in bit and slowly open the hole checking as you go so as not to over do it . D. Text me your contact info and I'll make a template and send it to you no charge. The only cost to you would be to hook a brother up who is in need at some point in the future....you know, The pay it forward kinda deal. Shop # 951-676-0191. da Bat....Jeff Miller

[Blitzboy54]

Three ways to do it. A. Find a car near you and ask the owner if you can make a template. 2. Start with a small tube inside the rollbar bung , mark the bottom, drill up with 1/2in bit and slowly open the hole checking as you go so as not to over do it . D. Text me your contact info and I'll make a template and send it to you no charge. The only cost to you would be to hook a brother up who is in need at some point in the future....you know, The pay it forward kinda deal. Shop # 951-676-0191. da Bat....Jeff Miller

The Jeff's on this board are just the best.

[Rdone585]

You will need to also weld in the mounting points if they aren't already in. That will be much easier done with body off.

[mikeinatlanta]

My body was undrilled and I marked similar to what Jeff said. DOM tubing has no seam inside so a couple of properly sized lengths slide over each other nicely and allow easy marking of the body from underneath.

Wouldn't even try to weld in mounts with the body on.

[Jeff Kleiner]

Mk4’s have the chassis tubes welded to the chassis whether they were ordered with a passenger roll bar or not. I’ve used big & little combinations of plastic pipe to make a “telescope” like Mike described and then used that to project the locations of the chassis stubs to the underside of the body.

Jeff

[rich grsc]

Drop a length of pipe into the mount, then drop a flashlight into that. Turn off the lights and you should be able to see the flashlight through the body

[j.miller]

Drop a length of pipe into the mount, then drop a flashlight into that. Turn off the lights and you should be able to see the flashlight through the body

NOW THAT !...... is just Voodoo talk.....never work in a million years.....This guy is a shyster, hoolagan, nerdewell with this cacamaimy.......Ok, It could work....worth a shot....now I'm really interested...da Bat

[rich grsc]

A double shot of Rum, and it'll work.:eek: If not, double that until it does. :rolleyes:
A nerdwell??? really. I'm telling

[Hoodlum60]

Thanks guys, I really appreciate the help. All of my experience similar to this is boat rigging. I generally use a hole saw for gauges, which would be the closest to this. If I can’t find a center spot for the guide bit in the hole saw, I’ll have to figure out how to make my hole. If I could center the flashlight in the pipe that may just work. (Great Idea!) I normally drill on the finished side through painters tape to make the hole as clean as possible. I could drill a small pilot hole from the bottom. Anyway, thanks again for all the suggestions!

[Jeff Kleiner]

Drop a length of pipe into the mount, then drop a flashlight into that. Turn off the lights and you should be able to see the flashlight through the body


Light would work if it was raw glass or even still in gelcoat but not after paint.

Jeff

[egchewy79]

how about a magnet? glue a strong magnet to the end of a PVC pipe with a closed end and fit that over the roll bar stubs. then use another small strong magnet to show the center of the tube on the body side. trace that out, and drill out the hole, then slowly open it up with a dremel tool.

[Rdone585]

High power laser mounted in the center of the tube inside the truck. Just burn a hole right through the body where the center of the hole should go. :eek: Then drill the full hole from the paint side of the body. :rolleyes: OK maybe the laser isn't such a great idea after all, burned a hole in the ceiling of the garage. Oh now lets get back to reality...

How about mounting a small Dremel tool inside the plastic pipe telescope. Want to make sure the bit you use isn't too long so it has less of a chance to break off.

[DAVID_T]

I might be late to the party, but before you go the template route, double check your roll bar.
I ordered a passenger roll bar after I decided I wanted one, and needed to add a third mounting post to the frame (the hoop mounts were in place from F5). I mirrored the driver side and welded it on while it was being shipped. Turns out, it was about an inch off. My passenger bar has a different angle on the back bar. I had to cut it off, grind the frame clean and then reweld it. I did attempt to install it thinking it might bend into place, and it starting binding and wouldn't set on the frame.

Good thing I hadn't cut the body holes out, as it is, if you look from the side carefully you will notice that the bars are not exactly in line with each other. A cursory look doesn't reveal it.

For what it is worth.

What I did is once I had the hoops in place, I used paper towel cardboard rolls to get my angles and mark spots for my hole saw. Came out great, and the holes are right where they need to be.

[j.miller]

High power laser mounted in the center of the tube inside the truck. Just burn a hole right through the body where the center of the hole should go. :eek: Then drill the full hole from the paint side of the body. :rolleyes: OK maybe the laser isn't such a great idea after all, burned a hole in the ceiling of the garage. Oh now lets get back to reality...

How about mounting a small Dremel tool inside the plastic pipe telescope. Want to make sure the bit you use isn't too long so it has less of a chance to break off.



HIGH POWERED LASER !! Good god it's turning into a real party !! You bring the laser , I've got a generator that can put out 1.21 Gigawatts and I'll get Kleiner to bring the teaspoon...da Bat

[Hacksaw84]

I had to cut mine in gelcoat bc I shortened my bars and that brought the leg in. The technique I came up with would help you for the 3rd leg part too. I figured out a general center but using a laser and a wood jig. I cut an undersized hole, then I attached a series of strings to the outside of both ends of the mounts. I just kept cutting till the string didn't hit the body anymore. That would be after you get the two uprights done. I would think you could find a pipe to slip in or out of the body mounts to line it up from the inside. Or if you were precise enough with a laser jig it would give you the center to dill a pilot hole from under and then could come at it from the top with a hold saw.

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