Roll Cage Build - The Ford Focus Forum

**mattm2001** · 09-25-2008, 11:51 PM

Well, the time has come... Tomorrow im starting my roll cage in my 2001. Ill use this thread to post updates, costs and pics.

Cost so far:
Tubing-60ft- $361.61=DOM 1.75x.120, i know the wall is thicker but thats all i could get.

Just an exterior shot of my focus at an autocross with the racing slicks and wheels. (sep 13)

**jinstall** · 09-26-2008, 09:28 AM

Cool I will keep an eye on this thread.

**Silonius** · 09-26-2008, 10:43 PM

Excellent! Can't wait to see what's involved!

Are you doing the welding and bending yourself?

**mattm2001** · 09-27-2008, 12:37 AM

yes doing all welding and bending myself, ill have pics and stuff tomorrow hopefully. & also, this thread is mainly so you guys can ask questions and ill try to answer them.. I dont plan on posting a step by step. But ill try to explain what im doing.

**mattm2001** · 10-06-2008, 05:06 PM

first gut the car

Heres my roll cage main hoop jig with the bar and the first bends completed

and here it is after second bends completed

now all i have to do is make the floor mounts and fit

sorry its taking me so long, but i have a messed up knee and back from work so im slowly getting it done

**Plan B Racing** · 10-06-2008, 10:23 PM

what type of bender are you using to make your bends?

**mattm2001** · 10-07-2008, 02:31 PM

just an el cheapo bender from harbor freight. but i dont own it, im borrowing it from a friend.

**Plan B Racing** · 10-07-2008, 02:52 PM

be careful using this type of bender, if it crimps too much in the bends it won't pass scrutineering. take detailed photo's and send them to a scrutineer while you're building your cage, that way you won't run into problems when you show up for your first race.

**mattm2001** · 10-07-2008, 06:10 PM

i didnt show me filling them with sand. but i did, and also im using .120 wall so crimping really wouldnt matter in this case. if i was using the.95 wall then i would worry about tech inspection. but thank you. do you know the email adress of the nearest scruteneer to georgia?

**tparker** · 10-07-2008, 11:13 PM

What is the full length of the main hoop?

**mattm2001** · 10-07-2008, 11:34 PM

Quote:

Originally Posted by tparker

What is the full length of the main hoop?

I did mine at 150" so id have a little extra screw up room. But it really all depends on where you mount the main hoop. Im so tall i have to mound the main hoop on the shelf were the rear seat goes, so the hoop is shorter, but i also have to rebuild the floor there with 1/8" steel plate and then reinforce that. If you mount on the floor, id cut it to 150 cuz i had plenty overlap.

**Plan B Racing** · 10-08-2008, 12:21 AM

Not sure where you are in GA but here is one listed on NASA Rally Sport as a scrutineer. Make sure you read thru the rules and get to know them well, it will help alot when fabricating a cage. "An ounce of prevention..."

Gary D'Abate
363 Spring Crest Rd
Cleveland, GA 30528
Phone 706-219-6447
dab8_scca@yahoo.com

**Silonius** · 10-14-2008, 10:22 AM

Quote:

Originally Posted by Plan B Racing

what type of bender are you using to make your bends?

Hehehe, this popped in my head.

Sorry to hear about the back, good luck finishing it!

**mattm2001** · 10-19-2008, 10:14 PM

I regret to inform you that the roll cage build is being put on hold indefinately because of my knees, and i dont have enough time.
again sry

**mattm2001** · 01-09-2009, 01:29 PM

The Focus Is back on Baby

, Woot! More pics in a bit!!!

**sleeperlove** · 01-10-2009, 04:07 PM

Quote:

Originally Posted by mattm2001

The Focus Is back on Baby

, Woot! More pics in a bit!!!

w00t!

**Silonius** · 01-13-2009, 05:54 PM

Hooray!

**topspeedfab** · 01-14-2009, 09:37 AM

Quote:

Originally Posted by mattm2001

The Focus Is back on Baby

, Woot! More pics in a bit!!!

I'm ready to see more!

**getn2focus** · 01-14-2009, 08:20 PM

I have been waiting for this build to resume. Good thing! Hope all is well and goes smooth. Looking forward to the rest.

**mattm2001** · 01-24-2009, 12:44 PM

Ok, Ive decided to get a bit more serious on my rally focus, becuase i want to do so many things to this focus it might only be able to run M2. But heres the updates.

First start with a body shell.

Stock wiring harness... Who needs that pffft.. lol

Starting the stich welding

P.S. This will probably turn into a build thread.

**s.carlson** · 01-25-2009, 03:58 PM

Just a bit of constructive critisism. Your beads are to high, should be more flat. What kind of welder are you using?

**rallyrat** · 02-12-2009, 10:37 AM

Don't forget to gusset the transmission support bracket to the body.

Ken

**alk.3_st** · 02-12-2009, 01:57 PM

This makes me even more excited to do mine when summer comes around. Atleast you have strong floorboards

. Good luck with the project.

**2.3focuszx3** · 02-14-2009, 09:04 AM

**Fun Fact for better bends with your bender... spray the bender with WD-40 the bender wont pinch it. also welding to a unibody is VERY hard to do without burning holes all over. you may need to weld steel plates down then weld to those, this way you displace the load over the plate and not in the point of the end of the bar. i have put a roll cage in a rally neon 2nd gen and ran into these problems and hind sight is 20/20. good luck dont total your focus.

**topspeed** · 02-16-2009, 11:58 AM

any more updates?

09-25-2008, 11:51 PM	#1 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Roll Cage Build Well, the time has come... Tomorrow im starting my roll cage in my 2001. Ill use this thread to post updates, costs and pics. Cost so far: Tubing-60ft- $361.61=DOM 1.75x.120, i know the wall is thicker but thats all i could get. Just an exterior shot of my focus at an autocross with the racing slicks and wheels. (sep 13) __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here Last edited by mattm2001; 09-26-2008 at 12:45 AM.

09-26-2008, 09:28 AM	#2 (permalink)
jinstall [FJ] Addict Join Date: Feb 2001 Location: Manassas/Ft Belvoir VA Posts: 13,897	Re: Roll Cage Build Cool I will keep an eye on this thread. __________________ NRA Range Safety Officer Apr 2009 2001 ZX3 Race Car sleeping in Germany (was his) 2006 Jeep Liberty CRD (His) 2004 Renault Clio 1.2 16V in Germany (hers) 2008 Trek 4300 (his) 2009 Diamondback Response Sport (hers)

09-26-2008, 10:43 PM	#3 (permalink)
Silonius TEAM Member Join Date: Aug 2004 Location: Denver, CO Posts: 727	Re: Roll Cage Build Excellent! Can't wait to see what's involved! Are you doing the welding and bending yourself? __________________ 2004 Black ZX3 Zetec BAT springs,Ford Racing short shifter, Falken RT 615 205/50/15 Underdrive pulley and shorty header, H&R 5mm spacers and hardened lugs, Hawk HP+ front pads, SPC camber plates Up next short term: Replace header, timing belt and water pump Up next long term: cage and Rally Spec Focus!

09-27-2008, 12:37 AM	#4 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build yes doing all welding and bending myself, ill have pics and stuff tomorrow hopefully. & also, this thread is mainly so you guys can ask questions and ill try to answer them.. I dont plan on posting a step by step. But ill try to explain what im doing. __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

10-06-2008, 05:06 PM	#5 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build first gut the car Heres my roll cage main hoop jig with the bar and the first bends completed and here it is after second bends completed now all i have to do is make the floor mounts and fit sorry its taking me so long, but i have a messed up knee and back from work so im slowly getting it done __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

10-06-2008, 10:23 PM	#6 (permalink)
Plan B Racing TEAM Member Join Date: Dec 2006 Location: Ridgecrest Ca. Posts: 351	Re: Roll Cage Build what type of bender are you using to make your bends? __________________ 1994 Mitsubishi Diamante Wagon 5spd Turbo Monster 1989 Mazada 323 GTX Rally Car 2002 Ford Focus SVT Rally Car

10-07-2008, 02:31 PM	#7 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build just an el cheapo bender from harbor freight. but i dont own it, im borrowing it from a friend. __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

10-07-2008, 02:52 PM	#8 (permalink)
Plan B Racing TEAM Member Join Date: Dec 2006 Location: Ridgecrest Ca. Posts: 351	Re: Roll Cage Build be careful using this type of bender, if it crimps too much in the bends it won't pass scrutineering. take detailed photo's and send them to a scrutineer while you're building your cage, that way you won't run into problems when you show up for your first race. __________________ 1994 Mitsubishi Diamante Wagon 5spd Turbo Monster 1989 Mazada 323 GTX Rally Car 2002 Ford Focus SVT Rally Car

10-07-2008, 06:10 PM	#9 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build i didnt show me filling them with sand. but i did, and also im using .120 wall so crimping really wouldnt matter in this case. if i was using the.95 wall then i would worry about tech inspection. but thank you. do you know the email adress of the nearest scruteneer to georgia? __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

10-07-2008, 11:13 PM	#10 (permalink)
tparker Moderator Join Date: Nov 2004 Location: @ the drag strip, auto X, road race & AZ G2G Posts: 3,289	Re: Roll Cage Build What is the full length of the main hoop? __________________ FS/VF SC w/IC blow thru mod 13.495 @ 102.306 best 1/4 current set up. July 06 FOTM My Focus Web Page JCM Racing #10

10-08-2008, 12:21 AM	#12 (permalink)
Plan B Racing TEAM Member Join Date: Dec 2006 Location: Ridgecrest Ca. Posts: 351	Re: Roll Cage Build Not sure where you are in GA but here is one listed on NASA Rally Sport as a scrutineer. Make sure you read thru the rules and get to know them well, it will help alot when fabricating a cage. "An ounce of prevention..." Gary D'Abate 363 Spring Crest Rd Cleveland, GA 30528 Phone 706-219-6447 dab8_scca@yahoo.com __________________ 1994 Mitsubishi Diamante Wagon 5spd Turbo Monster 1989 Mazada 323 GTX Rally Car 2002 Ford Focus SVT Rally Car

10-19-2008, 10:14 PM	#14 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build I regret to inform you that the roll cage build is being put on hold indefinately because of my knees, and i dont have enough time. again sry __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

01-09-2009, 01:29 PM	#15 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build The Focus Is back on Baby, Woot! More pics in a bit!!! __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

01-13-2009, 05:54 PM	#17 (permalink)
Silonius TEAM Member Join Date: Aug 2004 Location: Denver, CO Posts: 727	Re: Roll Cage Build Hooray! __________________ 2004 Black ZX3 Zetec BAT springs,Ford Racing short shifter, Falken RT 615 205/50/15 Underdrive pulley and shorty header, H&R 5mm spacers and hardened lugs, Hawk HP+ front pads, SPC camber plates Up next short term: Replace header, timing belt and water pump Up next long term: cage and Rally Spec Focus!

01-14-2009, 08:20 PM	#19 (permalink)
getn2focus TEAM Member Join Date: Feb 2008 Location: Mid TN Posts: 561	Re: Roll Cage Build I have been waiting for this build to resume. Good thing! Hope all is well and goes smooth. Looking forward to the rest. __________________ *Black 2003 SVTF* >>> E Prep Auto-X monster** What to do when you roll a rental car in an auto-x? "You quickly roll/tow/carry it onto a public road and THEN call the rental agency." -- GtnMaZumOn

02-16-2009, 11:58 AM	#25 (permalink)
topspeed Premier Sponsor Join Date: Jul 2008 Location: Greenville, NC Posts: 71	Re: Roll Cage Build any more updates? __________________ Chris Emanuel @ Top Speed (252) 321-6356 Top Speed, INC \| Our eBay Store \| Top Speed Online Store \| Blog \| Contact Us Be sure to check out our daily blog updates! \| The Best Way to Contact Me is by Email or Phone!

01-24-2009, 12:44 PM	#20 (permalink)
mattm2001 TEAM Member Join Date: Jun 2008 Posts: 257	Re: Roll Cage Build Ok, Ive decided to get a bit more serious on my rally focus, becuase i want to do so many things to this focus it might only be able to run M2. But heres the updates. First start with a body shell. Stock wiring harness... Who needs that pffft.. lol Starting the stich welding P.S. This will probably turn into a build thread. __________________ R.I.P Colin Mcrae. You were, and always will be the best rally driver. 1968-2007 Ford Focus Rally Car Build Thread Click Here

01-25-2009, 03:58 PM	#21 (permalink)
s.carlson Rookie Join Date: Jan 2009 Posts: 9	Re: Roll Cage Build Just a bit of constructive critisism. Your beads are to high, should be more flat. What kind of welder are you using?

02-12-2009, 10:37 AM	#22 (permalink)
rallyrat TEAM Member Join Date: Sep 2000 Location: Cleveland, Ohio USA Posts: 176	Re: Roll Cage Build Don't forget to gusset the transmission support bracket to the body. Ken

02-12-2009, 01:57 PM	#23 (permalink)
alk.3_st TEAM Member Join Date: Jan 2008 Location: 262, WI Posts: 151	Re: Roll Cage Build This makes me even more excited to do mine when summer comes around. Atleast you have strong floorboards . Good luck with the project. __________________ '07 Focus ST '89 VW Golf

02-14-2009, 09:04 AM	#24 (permalink)
2.3focuszx3 TEAM Member Join Date: Nov 2006 Posts: 326	Re: Roll Cage Build **Fun Fact for better bends with your bender... spray the bender with WD-40 the bender wont pinch it. also welding to a unibody is VERY hard to do without burning holes all over. you may need to weld steel plates down then weld to those, this way you displace the load over the plate and not in the point of the end of the bar. i have put a roll cage in a rally neon 2nd gen and ran into these problems and hind sight is 20/20. good luck dont total your focus. __________________ llllllllllllllllllllllllllllllllllllll lllllllllllllllllllllllllllllllllllllllll lllllllllllllllllllllllllllllllllllllllll lllllllllllllllllllllllllllllllllllll 07 toreador red zx3 2.0 slight mods

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