Roll bar pipes aren't lining up...

[Slider]

Well, I'm getting to the end of the build, and it seems that the last few parts have been fighting me tooth and nail. Now, one that should have been pretty simple if giving me grief.

I'm running dual roll bars. Passenger side fit perfectly. The drivers side however seems to have an angle off slightly, causing an unsightly gap where the hoop and the rear support bar come (seam) together. We sanded and reamed the pipes to get a little more play to try and fit them together, which made it better, but still a noticeable gap, especially since the gap is right behind the drivers head. As you will see in the pictures, the gap is only on one side of the pipe (toward the front), and it doesn't matter how I turn the rear bar, the gap stays in the front. When I remove them from the car, they match up perfectly, so its not a "pipe fitting" problem. It would appear to be that the short angle piece coming off the main part of the bar, or the connection point in the trunk for the rear support bar might be just a hair off.

Given all the time and effort thats gone into finishing the car, I really don't want to "live" with the little gap. Has anyone else experienced this, or have any ideas on how to resolve? The easiest would be to shave the top of the bar where the gap is (back side), but with Chromed parts, that really isn't an option.

Please let me know if you have any questions. Pictures are attached.166431664416645

[Slider]

I've adjusted the rollbar heights on each side and the passenger is still perfect, and the drivers side is better, but still a bit of a gap... Not sure what else I can do. if there are any ideas out there, please let me know...

[frankeeski]

Slider, your best bet is going to be pulling the body. I know you don't want to hear that but, that is the only way you can persuade the rear mount to the position you need. Take a longer length of pipe and tweak the rear mount a bit to get the bar slip fit to line up. It is a pretty common problem that most guys would just live with but if you want perfection you are going to have to work for it. Welding makes things move, so no matter how hard FFR tries to line everything up things like this do happen.

[DaleG]

Sure can't live with that. I think that Frank's solution is the only way. And I'm surprized at the gnarly-looking weld they chromed over.

[Jester]

Slider

You may want to check the bulb seal and reposition the body to get a better fit. The body can be lifted and shifter slightly where required.

Good luck

[Slider]

Jester, I've done some wiggling of the body to fix a couple of other issues, and agree with you that you can make some difference on some items. Unfortunately, the rollbar issue was present even before I put the body on. I think by raising the bar slightly I've got the gap (from pictures) reduced to a fairly unnoticeable level. I may try a little bend as mentioned above when the body goes off to paint.
Slider

You may want to check the bulb seal and reposition the body to get a better fit. The body can be lifted and shifter slightly where required.

Good luck

[Tyler Wayne]

You can make a homemade drum sander to sand the inside of the roll bar to give a little more wiggle room. Wrap a socket slightly smaller than the ID with some 60-120 grit sandpaper strip and tape it so the ending flap overlaps the tape. Attach to drill and you can remove some material in the inside of the roll bar. I did this mainly to get some tolerance on the third leg attaching at the hoop.

I had the same issue that you do with my MK4. However I lowered my rollbars 1.5" and had to cut out and reweld the third leg mounting posts, as well as open up the body hole.

http://i56.photobucket.com/albums/g172/twyluh/IMG_3032_zps10cd7168.jpg (http://s56.photobucket.com/user/twyluh/media/IMG_3032_zps10cd7168.jpg.html)

http://i56.photobucket.com/albums/g172/twyluh/IMG_0144_zpsb78a30b4.jpg (http://s56.photobucket.com/user/twyluh/media/IMG_0144_zpsb78a30b4.jpg.html)

Ultimately repositioning the third roll bar mounting posts worked for me get a nice tight fit, but you may be able to sand and bend to help yours....

[Slider]

Thanks Tyler, I've got them lining up pretty well now, but may try the sanding as you suggest to get them a little better. I'd used a dremel and one of the small sanding drums to do as you suggest to get more room, but I think your homemade drum might work better. Really appreciate the ideas. BTW... your car looks GREAT! Nice job. Mine goes to paint on Monday, and currently I have everything installed so I know it works/fits. I'm getting a little emotional with the thought of taking it apart and taking the body off again... It's tough to have it feel like its down only to rip 'er all apart again...