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WRC style gussets for rollcage.

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  • BELLBOYMOTORSPORTS
    replied
    i really do try to respond on thing i know and rally is one of my passions and i figured out i could help steer this in the right direction since building rally cars and off road vehicles is why i decided to learn tig welding

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  • H80N
    replied
    Bellboy
    good thought... shot off an email to VSC.... see what we get....

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  • BELLBOYMOTORSPORTS
    replied
    Future rally car builder

    this is a question best suited for company's like M-Sport or Vermont SportsCar since the are the builders of the most rally cars that I know of plus if im not mistaken were the first to cage the new ford fiestas which is where that second pic came from. M-Sport is the only ford backed major team in the WRC and Vermont Sportscar built Ken Blocks new fiesta and all Travis pastrana's Subaru WRX's for rally America and Xgames. Just check some of my info the in car pic posted is indeed from a M-Sport built ford fiesta rally car
    Last edited by BELLBOYMOTORSPORTS; 12-04-2011, 05:50 AM. Reason: FACT CHECK

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  • H80N
    replied
    Suvi
    I enhanced and blew up thathe Taco Shell detail on that Tuareg Rally chassis you provided.. maybe somebody has a clue as to the supplier.. or a supplier of stampings with curvature...similar...


    Click image for larger version

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  • H80N
    replied
    Originally posted by Suvi View Post
    But as you think that to make it in two pieces, should be really easy. It should be possible to make dolly even out of wood. Clamp sheet flat and tight to curved shaped dolly and hammer it over with wooden or plastic hammer. (it should leave very good surface) make 2 pieces, trim them and weld.

    You quote Estonian saying saying in your signature. Any connection with the country?
    I would have to sit down and read the rules but if allowable I would CNC some hammerforms and make the halves... will have to explore the rules to find out... here is a link to the FIA Docs..

    http://www.fia.com/sport/Regulations/rallyregs.html

    as per your second question... I sent you a PM....
    Last edited by H80N; 11-28-2011, 11:33 PM.

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  • Suvi
    replied
    Googled a little. And here did one guy use hammerforming to do somehting similar
    http://img7.imageshack.us/img7/5779/imgp5746.jpg
    http://img845.imageshack.us/img845/4056/imgp5720.jpg
    http://img405.imageshack.us/img405/7240/imgp5721v.jpg

    But still this 2 piece seems to be the half way for me. Hope we can figure it out how these can be made in one piece with not so expensive and hard way.

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  • Suvi
    replied
    But i think it's a rule that gusset for rollcage has to be made out of one piece?
    From Appendix B – Roll Cage Construction
    "U-shaped sheet metal (taco shell). Refer to figure 253-
    34 below. Minimum thickness is .040” (1 mm). Minimum
    length along the unwelded side of the gusset is 3 times
    the tubing diameter"


    But as you think that to make it in two pieces, should be really easy. It should be possible to make dolly even out of wood. Clamp sheet flat and tight to curved shaped dolly and hammer it over with wooden or plastic hammer. (it should leave very good surface) make 2 pieces, trim them and weld.


    You quote Estonian saying saying in your signature. Any connection with the country?
    Last edited by Suvi; 11-28-2011, 04:41 PM.

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  • H80N
    replied
    The pre made "Taco Shell" gussets that I am finding are straight not gracefully curved like your examples...

    http://www.pacificcustoms.com/rollcages.html

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  • H80N
    replied
    Suvi
    if not made from tube and plates it could have been made from two pieces with the weld seam along the center of the curvature... that is how I would do it in my shop.... in order produce that part as a single piece... it would take a large industrial press.... those parts may be available but I have not seen them..(would take a lot of power to stamp those shapes...)

    you have aroused my curiosity though... I will do some looking and asking around and see what I can find,,,,

    also Andy Weyenberg, the super-moderator here knows a lot about cage and chassis fab... having many years experience with NASCAR construction... maybe he will have some info to enlighten us...

    BTW... here is a link to the NASA Rally cage guidelines... they may be helpful...

    http://www.nasarallysport.com/rules-...Appendix-B.pdf

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  • Suvi
    replied
    i think you are looking at the rihght part. but it seems that is made in one piece instead.

    There is no sign of welding or head affected zone here.

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  • H80N
    replied
    Suvi
    if I am looking at the right part of your pics.... it looks like they are bandsawed out of prebent tube then plated on top.... and Tigged together..

    Heiti

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  • Suvi
    started a topic WRC style gussets for rollcage.

    WRC style gussets for rollcage.

    Hi

    There aren't really many pic's of these on the internet.
    here are few.
    http://image.europeancarweb.com/f/10..._roll_cage.jpg
    http://octanereport.com/upload/image...ta-wrc-001.jpg

    Anyone know how these curved gussets are made in one piece? I was think that first you need to bend the sheetmetal and then use roll bending machine with some special dies to give it arc?

    Any ideas?
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