I've done about 5 cars worth of gussets including mine and have made maybe $150-175 and paid maybe $90 for the die and $60 worth of metal for around break even.
I personally just like the look of the cool guy gussets to the a and b pillars, the extra support/stiffness is just an extra benefit. With a car as puke worthy as a Merkur you gotta do all you can to make it look cool.

---

Grant Hughes

hahaha. Very true...

Where did you pick the die up from? 4x4 fab site?

---

Welcome to the cult of JVL drink the koolaid or be banned.

I want to say it was called Miller Machinery or something like that. It was like 3 or 4 years ago. It had a bolt and I did a few with a wrench then said fuck it and ground off the threads and used a hydraulic press from then on.

So I just started to type Miller and realized it was actually Mitler brothers as I was typing. My memory works sometimes.
http://www.mittlerbros.com/punch__flares.htm
$95 now. I'd loan mine out if someone wanted to use it though probably.

---

Grant Hughes

Or!!!
for all you non-high roller guys further down Mittler Bros list are these where you use a hold saw first. Less than half the price.
Qty: $40.00

1300-001 1/2" Flare Tool


2Lbs.


Qty: $40.00

1300-002 5/8" Flare Tool


2 Lbs.


Qty: $40.00

1300-003 3/4" Flare Tool


2 Lbs.


Qty: $40.00

1300-004 1" Flare Tool


3 Lbs.


Qty: $40.00

1300-005 1-1/4" Flare Tool


3 Lbs.


Qty: $45.00

1300-006 1-1/2" Flare Tool


4 Lbs.

---

John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

john, for us uber cheap guys--- what do you charge to borrow your hole-saw and flare tools??? =)

NoCoast Wrote:
-------------------------------------------------------

> I personally just like the look of the cool guy
> gussets to the a and b pillars, the extra
> support/stiffness is just an extra benefit. With
> a car as puke worthy as a Merkur you gotta do all
> you can to make it look cool.
>
> Grant Hughes
> www.nocoastmotorsports.net
> Denver, CO

Yes, but you welded them in with the dimples 'upside down'!

I know. I was so pissed at myself. I did the other side the other way I think. I'll have to go look one of these days.

---

Grant Hughes

starion887 Wrote:
-------------------------------------------------------
> NoCoast Wrote:
> --------------------------------------------------
> -----
>
> > I personally just like the look of the cool
> guy
> > gussets to the a and b pillars, the extra
> > support/stiffness is just an extra benefit.
> With
> > a car as puke worthy as a Merkur you gotta do
> all
> > you can to make it look cool.
> >
> > Grant Hughes
> > www.nocoastmotorsports.net
> > Denver, CO
>
> Yes, but you welded them in with the dimples
> 'upside down'!
>
>
>

But they look good from the inside....

The best source for best info is original homologation papers. The factories spend 100s of hours designing the best possible protection for best weight for any body style. These ideas can be copied to other cars.
Here's some from Mitsu: http://www.ralliart.com/GRN/homologation/x.html
Rigth now most improvements are side protection and A-pillar support. The reason is many insuried and deaths.
I don't see you got straight-up support at door. It doesn't help to weld brazes when windshield pillar is very slanted. It needs an extra support. See Mitsu pics.
NOTE: Many secondary support pipes DOES NOT need to be same thickness as in the US is common. It just makes the cage heavy. Again, see the factory cage pics.
Good luck with your business! We need more quality minded fabricators. Dave Clark and other good "old times" have to retire one day...

---

- RWD rocks -

heymagic Wrote:
-------------------------------------------------------
> starion887 Wrote:
> --------------------------------------------------
> >
> > Yes, but you welded them in with the dimples
> > 'upside down'!
> >
> >
> >
>
> But they look good from the inside....
>
>
Ya know, I never thoguht of that! You're a "glass half full" type of guy, Gene!

Thanks for the info. I agree that the factories know what each car needs better than most guys like me could ever figure out. I don't think that one manufacturer has all the best ideas though. I like to steal the best of them for my own financial gain, ha ha. That xr4ti in the picture is my car that doesn't need to be RA legal, and the a pillar support is in the way just to much. I didn't put sill bars either. They could be added later if I needed to. Thank to all of you guys for the good advice and support. Talk to ya later OB