ClioSport.net

Register a free account today to become a member!
Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members through your own private inbox!

182 Full Custom Roll Cage Design



FPummell

ClioSport Club Member
Hello All,

Nearly completed stripping a 182 to turn it into a track car so been discussing what to do with the roll cage. So would be great to hear peoples thoughts and ideas to make a better roll cage.

Ideally would want to have a Custom Cages multipoint weld in cage (like below) but without the cost.

fullsizeoutput_15f6.jpeg


So! My friend and I (co owners) have decided to try and design and build our own. The idea being that we would get Tube Bender Tom to bend the main hoop and front side pieces then the rest would be up to ourselves.

First step was to measure up the Clio and make a first iteration of the main hoop and front sides. Got the Clio level on axle stands then used a 360 degree laser to create 3 planes within the car to allow me to measure X, Y and Z co-ordinates of hard points and bend points.

jkDunhDeQVSBobiQyfl%Fw.jpg

f3pyM9FjTHeCOG4b8LxDzQ.jpg


With one of the planes lined up with where i reckoned the main hoop should be i used pipe insulation to represent the tube. The pipe insulation conveniently was just under 50mm and a glue gun was perfect to stick the insulation in place.

NwmyT2roTBqnXSCXesu1FQ.jpg


With the pipe insulation in place i then set about measuring a number of different points to give me X, Y and Z co-ordinates which will then be used to create a CAD model of the cage. Was really easy measuring the points using the laser planes so didn't take as long as i thought.

CKb3xMSmS6Sp4vAf8MORJQ.jpg

xC3DAhDkReyS8ptCUP+LDg.jpg


With about 10 points measured I started with an initial CAD model. The plan is to print out the main hoop as a 2D full size drawing at work to then allow me to check the fit inside the car. Then can go through a few iterations of the main hoop until i am happy with it. Unsure on what sort of clearance to leave between the tube and the body. Just enough space to allow me to get the welder in?

fullsizeoutput_15cd.jpeg


So this is what I ended up with using the measured points. I put some nominal bend radii in there for the time being. Need to check with Tom or who ever eventually bends the tube if i need to stick with certain radii or not.

Then got a bit carried away on CAD, hopefully this is what it would end up like.

fullsizeoutput_15ce.jpeg


Obviously need to measure where all the other tubes need to go and check they will fit but more concerned about getting the main hoop correct along with the front upper side tubes as these would need bending. Then hopefully the rest can be done with straight tubes, hence can just cut and notch those myself.

Will add more detail into the CAD model once i start to get the correct shape. Planning on just following the MSA regs with regarding thickness, grade etc.

Would be great to hear your thoughts and whether I am heading in the right direction with it or missing out something crucial out.

Hoping at the end of it i will be able to send out the drawings/CAD model so others can get the tubes bent themselves.

If people show an interest in this I may start a proper build thread as I have found other peoples very useful, particularly TomoTek's build.

Hope to show some more progress shortly.
 

Woznaldo

ClioSport Club Member
  Renault 5 GT Turbo
I’m looking to do the same for my R5 GTT. What I have noticed is most cages for Renaults don’t tie in the rear suspension properly. This is especially the case with R5 and Clio1.

Looks like you are using Catia CAD, so the benefit will be the ability to assess the torsional stiffness with the onboard FEA.
 
It'll be easier and cheaper to buy one from one of the manufacturers.

Given the learning and no doubt mistakes along the way.
 

Woznaldo

ClioSport Club Member
  Renault 5 GT Turbo
Caviat: You’ll need to make some assumptions about the body shell and attachment points when doing the FEA.
 

Woznaldo

ClioSport Club Member
  Renault 5 GT Turbo
Depending on what tubing you’re using (Mild Steel CDS, 4130N or T45) there will be different costs. If you plan on racing I’d check if the series allows T45 or 4130N. Ultimately, the two largest costs are the fab work (cutting, bending and notching) and welding. Best to use TIG to minimise heat affected zones, although this is less of an issue when using T45.

Also, a point of clarification. T45, 4130N and Mild Steel all have almost identical densities, so they all weigh the same. The lightness comes from T45 and 4130N being far stronger (higher tensile strength) and therefore thinner wall thicknesses can be used.
 
  406 V6, Race Buggy
You can only use thinner tubing if you get the cage designed certified by somewhere like MIRA as a 3rd party, you're looking at adding a grand to the cost of a one off-cage for that alone.
 
  Clio Sport
You can only use thinner tubing if you get the cage designed certified by somewhere like MIRA as a 3rd party, you're looking at adding a grand to the cost of a one off-cage for that alone.
I have not yet received the Dogbone I ordered from you on November 17th ..do you have the tracking number to the order..I haven't received anything in the last 2 weeks.. It seems my private message is broken because you haven't replied...
 
  Clio mk2 1.4 16v
Hi mate
Cool collection of data.
Is there any chane i could have the angles and lengths for the front a pillar part of the cage?
I have measured the rear and already sent out for bending but cant get to the car to measure the front for a while.

Thanks

Sent from my SM-J600FN using Tapatalk
 

FPummell

ClioSport Club Member
Hi mate
Cool collection of data.
Is there any chane i could have the angles and lengths for the front a pillar part of the cage?
I have measured the rear and already sent out for bending but cant get to the car to measure the front for a while.

Thanks

Sent from my SM-J600FN using Tapatalk
Yes of course. I will send you the drawing for it.
 


Top