Yet
Another
Rally
Golf

Making some progress on the "new" car.

Car was only $350...I wonder if I can get a movie deal?

I think you have to use at least 2" tape for the door bars

That's just a mockup...the real deal will be 2" duct tape...braided for strength.

Better go with Gorilla Tape then!

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Owner, Driver, Head Mechanic, and Janitor at Tower City Race Team, headquartered near L'Anse. Michigan.
Driver / CoDriver in Rally America, NASARallySport, ARA, AMS, UPMDA, Champ Off Road

https://www.facebook.com/TowerCityRaceTeam/
https://www.instagram.com/towercityraceteam/

How much work was it to take the roof off?

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

I didn't do it myself, but I believe it was fairly easy, just a bunch of spot welds and some seam sealer.

New non-sunroof roofs are $50 from VW, so it made sense to just cut off the sunroof roof and replace rather than fill the hole.

What color of cheese are you going to paint it?

Cheddar, of course.

Cage builder is having second thoughts on the door bar design.

Here's the two options, laid out in intermediate strength masking tape.

The sill bar is staying. So single cross bar, or an X?

The X will make connections to the A-pillar support much easier to do and gusset. But it does make it a bit harder to get in and out of the car.

Ask your self why the door bar is there, and go with the stronger design that is a slight bit harder for ingress/egress. Rember, they are there to keep stuff from making it into the car when you hit something. Take it from a guy who has hit a tree hard, make the door bars as strong as you can.

Sean, You could have saved a lot of text in that last post and just attached your "Tree 1 XR 0" pic.

You mean this one?

I went with the old school sill bar and angled door bar. I really like how easy it is to get in and out of the car.

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

We went with two bars in 1.75". I'm comfortable it will be plenty strong.



Some xXx action


Roof bars

+5 on what Robert said.
Sill bar, Single angled bar, and the a-pillar bar. Also means you don't have to add more gussets where the a-pillar support intersects the door bar since they don't anymore.

Quote
phlat65
Ask your self why the door bar is there, and go with the stronger design that is a slight bit harder for ingress/egress. Rember, they are there to keep stuff from making it into the car when you hit something. Take it from a guy who has hit a tree hard, make the door bars as strong as you can.

am I mis-remembering, or did you say you were thinking about/planning on nascar-style bars for the new shell?