Need a little 2" roll bar help

[Blitzboy54]

So I have been having some issues with the 2" roll bars. Mostly they keep showing up scratched and chipped real bad. FFR has a history of making this sort of thing right so I am not going to get too bent out of shape about it but we are now on multiple sets.

My real concern is I tried to mock up the first set and could not get the back tube to fit over the roll bar. I took a look and sure enough there was some over spray powder coating in there so I cleaned it up. I tried again and I mean, it won't fit and it's not that close so I measured with my calipers.

https://thefactoryfiveforum.com/attachment.php?attachmentid=204046&d=1726071441

https://thefactoryfiveforum.com/attachment.php?attachmentid=204045&d=1726071441

I am no rocket scientist but it seems like the outer part should be bigger than the inner part no? If I grind the stump to fit I will chip the heck out of the powder coat. I am working with FFR right now as I may just ask for credit and have the bars re shot since they keep showing up damaged anyhow. But for all you MkIII and earlier folks is this normal?

[herb427sc]

Opening up the the inside diameter of the down bar 1/16th of an inch should take care of the problem.
Use a carbide burr.

1.762 inches = 44.75 mm
1.750 inches = 44.44 mm

[cv2065]

Are you planning to cut out the rear mount and re-locate?

[Blitzboy54]

Opening up the the inside diameter of the down bar 1/16th of an inch should take care of the problem.
Use a carbide burr.

1.762 inches = 44.75 mm
1.750 inches = 44.44 mm

FFR is going to send me mild steel bars and give me a partial refund. It will be easier to do any mods, get them mocked up and drilled then powder coat them. I actually didn’t own a carbide burr. That will change tomorrow. Thank you for the help

[Blitzboy54]

Are you planning to cut out the rear mount and re-locate?

No sir, the geometry is the same as the 1.5 inch bars unless you shorten them. I actually don’t mind the height. If I was to trim them it would only be an inch or less and I just don’t see the work in relocating the back stud as worth it in that case.

[cv2065]

No sir, the geometry is the same as the 1.5 inch bars unless you shorten them. I actually don’t mind the height. If I was to trim them it would only be an inch or less and I just don’t see the work in relocating the back stud as worth it in that case.

Got it. Yes, the work to move it is quite a bit. I know that Michael Craven's build he cut and relocated and looks great, but again, a bit of effort to get there. I went down the middle of the road with Breeze's 1.75" bars. Will take a mobile welder to tack em in place, but shouldn't be an issue. I'm sure the 2" at any height will be a big improvement over the paperclips.

[Mike.Bray]

I love the way my Breeze bar looks.

https://www.imagecoast.com/images/MichaelBray1/20240425152626mediumrotated.jpg

https://www.imagecoast.com/images/MichaelBray1/20240517101109mediumrotated.jpg

[Blitzboy54]

I hear ya Mike. I am doing something a little different with this car, it is going to be a little off the wall. the 2" roll bars are an important element. I am more likely to go to the single roll cage that smaller bars at this point if I am being honest.

[OB6]

Hold on a sec :) The FFR site says the 2" bars won't fit the MK4. This thread is telling me otherwise. Why would FFR say they don't fit?

Asking because I like the thicker bars but always thought they wouldn't fit. Unfortunately the Breeze bars are too short for me, and I'm really not that tall (5-11).

[Blitzboy54]

Hold on a sec :) The FFR site says the 2" bars won't fit the MK4. This thread is telling me otherwise. Why would FFR say they don't fit?

Asking because I like the thicker bars but always thought they wouldn't fit. Unfortunately the Breeze bars are too short for me, and I'm really not that tall (5-11).

They fit in the sense that the geometry is the same. but they are 1.75 in ID. The studs are much smaller. you have to make sleeves using 1.25" I.D./1.75" O.D. .250 steel tubing. This will make them work but they don't "fit" from FFR's perspective.

[OB6]

They fit in the sense that the geometry is the same. but they are 1.75 in ID. The studs are much smaller. you have to make sleeves using 1.25" I.D./1.75" O.D. .250 steel tubing. This will make them work but they don't "fit" from FFR's perspective.

That makes total sense. I haven't actually seen them on a MK4, and I wonder how different they look. Anyone have any pictures?

[Blitzboy54]

That makes total sense. I haven't actually seen them on a MK4, and I wonder how different they look. Anyone have any pictures?

search "Hacksaw84" in the advance search under usernames. He did it on his build and posted some real nice grad pics. Absolute stunner of a build. He cut his down a bit a re welded the rear mount. Any pic of a MKIII would be the same as well.

[Jeff Kleiner]

That makes total sense. I haven't actually seen them on a MK4, and I wonder how different they look. Anyone have any pictures?

2 inch bars on a Mk4.

https://thefactoryfiveforum.com/attachment.php?attachmentid=204100&d=1726237245

https://thefactoryfiveforum.com/attachment.php?attachmentid=204101&d=1726237278

The top of the 2" bars whether on a Mk1,2,3 or 4 are exactly the same height as the 1.5" bars on a Mk4.

Jeff

[OB6]

Thanks Jeff, they definitely look more stout and less paperclip-ish. I think I'll try to source a set.

Edit: I just ordered a set from FFR.

[Lickity-Split]

Agree the 2" bar looks better. Although, I still like my Breeze bar also:

204114

[OB6]

Agree the 2" bar looks better. Although, I still like my Breeze bar also:

204114

I like the Breeze too, but my head sits just under it, so it's too short IMO to be effective.