WRC style gussets for rollcage.

[H80N]

WRX Wagon - Custom Roll Cage - Making a dimple die gusset.

Here is a VERY SIMPLE lo tech approach to dimpled gussets on a cage...

http://www.youtube.com/watch?v=M-Xp5Sr0604

[Electric4Life]

Gusset

I realize that this thread has been hangin on for awhile. I just looked at that gusset.

Seems a Pullmax could easily shape that profile. Of course, if you look at the gussets at the top of the A-Pillars in the picture, you can see the weld seam. It looks like a clamshell type gusset to me. For what its worth, they DO look nice.

[H80N]

While not exactly about the gussets.... these guys have dome some interesting things with how they have tied off suspension etc.. with the cage...

http://www.adgespeed.co.uk/preparation.asp

[H80N]

Thanks Suvi
Two pieces make the fabrication of those bits a whole lot simpler ....

[Suvi]

Been doing a lot research lately. And from reliable source i got told that all the curved gussets that VW racing cars have are made in 2 pieces.

Good hi-res pic
http://www.themotorreport.com.au/wp-...red-bull-1.jpg

[BELLBOYMOTORSPORTS]

It is the deep drawn stuff we are looking for.... hammerforming halves would be simple.... as would bandsawing prebent tube and fishplating.... BUT Drawn or Stamped...... they may come out of some corner of industry totally unrelated to racing....

id have to agree with you on that it might come from somewhere unrelated to racing im leaning toward it being stamped or requiring a lot of metal working skill

[H80N]

It is the deep drawn stuff we are looking for.... hammerforming halves would be simple.... as would bandsawing prebent tube and fishplating.... BUT Drawn or Stamped...... they may come out of some corner of industry totally unrelated to racing....

[chewinggum]

Those guys have infinitely deep pockets and do things the average shop can't do.
It looks to me like they are deep drawn and then trimmed into shape.
CG

[H80N]

OK here is the detail on the Tuareg cage



OK OK Bellboy.... I see what you are talking about where Suvi has posted the pic where it looks like a weld line on the B-pillar gusset painted white... think that is a real gusset though not a cover... not positive though....

[H80N]

Am looking for more plcs of the Dakar Tuareg cage for more detail of A-Pillar/windshield and B-pillar roof curved taco gussets.....

ran into this diversion..... a street concept.... pardon the detour...

http://www.autowallpaperhd.com/volks...cept-2011.html

[Even the stock street V10 diesel is formidable , younger brother has one... can light all 4 tires and go sideways if you punch it... something that the Cayene turbo S that I had, could not do... would love to put either engine in a 914... would be fun.... more likely to see an Iltis than anything powerful in these tight finances,,,]

[H80N]

so it sounds like VSC doesn't know how they are made either and i doubt custom cages are gonna tell you how they do it for free the two piece is good if all you want is the look but they are nowhere near as strong as the one piece would be plus i think the two piece thing you are looking at is actually a plastic cover to something because if you look where it meets the carbon fiber there is a ridge or something

Carbon fiber??? what carbon fiber?? what am I missing here?? plastic cover ditto????.......

[BELLBOYMOTORSPORTS]

so it sounds like VSC doesn't know how they are made either and i doubt custom cages are gonna tell you how they do it for free the two piece is good if all you want is the look but they are nowhere near as strong as the one piece would be plus i think the two piece thing you are looking at is actually a plastic cover to something because if you look where it meets the carbon fiber there is a ridge or something

[Suvi]

found this pic
Here you can really see that this gusset is made out of 2 pieces.


But this one in blue box seems to have no weld along the curvature. The heat should leave it's marks. But on other gussets on this frame it seems that they are made out of 2 pieces.

[H80N]

Vsc

Got a nice response back from Chris Yandel from VSC


"Typically those gussets are homologated as part of the supplied cage kit, and as such are supplied with the cage kit. We design and homologate our cage kits with Custom Cages who supply us the kits.

http://www.customcages.co.uk/homepage

Regards,
the Vermont SportsCar team"

[H80N]

would be nice to have a source for the deep drawn curved "taco shell" gussets...
thanks....