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Designing a roll bar
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pwozney
Posted 3/11/2015 10:45 PM (#83330)
Subject: Designing a roll bar


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I would like to put a roll bar in my sidecar, and I've made a first attempt at designing something.

http://imgur.com/OCkcfVp

There's a 2" tube frame that the tub sits on, and the porthole in the tub just obscures the rear tube, so if I want to have a roll bar coming straight up and out I need to either offset it forward by 2" (as in this design) or I'd need to have an internal bend.

I used a plate in the design, because I'm not sure how else to do this, but maybe that's okay. I'm not sure about the gussets either. Maybe I need an internal frame around the passenger too? I'm not expecting to protect anyone from a massive crush injury, but just to protect someone's head in the event of a rollover.

I'd definitely appreciate any design feedback here!
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pwozney
Posted 3/12/2015 1:14 PM (#83336 - in reply to #83330)
Subject: Re: Designing a roll bar


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I drew up another design that has gussets more elegantly integrated, but I really have no idea what I'm doing.

http://imgur.com/M322era

I might get some kind of clevis welded in at the bottom, so I can slip in the rest of the roll bar on top - otherwise I'll have to bore fairly large holes in the tub.
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Hack'n
Posted 3/12/2015 1:32 PM (#83337 - in reply to #83330)
Subject: Re: Designing a roll bar



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That one is a little bit better.

In order to be really functional the back bars need to be as high as possible with good triangulation.

Lonnie
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Al Olme
Posted 3/12/2015 4:19 PM (#83339 - in reply to #83337)
Subject: Re: Designing a roll bar


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Just my opinion but a combined rollbar and bumper that was all external to the tub would be a better solution and would require no holes in the tub. If I'm remembering correctly, you've already got the start of a surrounding bar. Carry the bumper around the back of the tub, weld a hoop to that and a stay from the top of the hoop down to the back of the surrounding bumper. Or is picture from post 83313 a different sidecar?
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pwozney
Posted 3/12/2015 4:46 PM (#83340 - in reply to #83339)
Subject: Re: Designing a roll bar


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a combined rollbar and bumper that was all external to the tub would be a better solution and would require no holes in the tub. ... Or is picture from post 83313 a different sidecar?


Same sidecar, and yeah I'll see how that would work. An external rollcage would be stronger and it would give me more room to work.

I'll see how it looks in the design.
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pwozney
Posted 3/12/2015 4:52 PM (#83341 - in reply to #83337)
Subject: Re: Designing a roll bar


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In order to be really functional the back bars need to be as high as possible with good triangulation.


Here's something with more triangulation: http://imgur.com/aqmvoCW
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Hack'n
Posted 3/12/2015 8:26 PM (#83342 - in reply to #83330)
Subject: Re: Designing a roll bar



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That's a hefty one but the single back bar would do it in this case.

Lonnie
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pwozney
Posted 3/13/2015 2:07 AM (#83349 - in reply to #83342)
Subject: Re: Designing a roll bar


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Hack'n - 3/12/2015 5:26 PM

That's a hefty one but the single back bar would do it in this case.


Good call. I think this is the last design I'm going to make, this is the same hoop but uses an external frame for bracing.

http://imgur.com/GfFPHVo

I measured and included the existing frame that's there, and I highlighted the section that would have to be added.

My next step is to call around to a few more places, and now that I've got something show them I might get more accurate quotes.

Thanks for your input everyone!
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Al Olme
Posted 3/13/2015 1:48 PM (#83355 - in reply to #83349)
Subject: Re: Designing a roll bar


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Location: Minneapolis, Minnesota
Now you've got it right!
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