Mike

Crown Vic Roll Bar Build

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17 posts in this topic

Current shop project for Cameron in Clarksville (LS turbo silver crown vic).  I measured everything up and had the cage bent by Chris Coffee Fabrication and Race Prep.  Then threw on my sandals and got to work.

 

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66sprint6 and mstrpth like this

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I got the door bar bent a little more and it fits great now.  I also got the harness bar bent and fit.  Just one more door bar remaining to fit then I get to weld for hours, updside down, standing on my head, balancing on one leg etc.

 

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66sprint6 and Ashley P like this

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What a cool car. BTW, the back seats are not very roomy when they have the bar n them esp for us bigger guys......so I've been told.

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I got a lot done today.  I fit the last bar, drivers door bar.

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If you use a harness that wraps around the roll bar (vs bolted), it needs a retainer.  So I made that.  The wrapped harness is a better choice also. 

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Then I tore it all back apart to start welding.  I drill a hole at every joint, so as the air in the tube gets hot and expands when welding, it has a place to go and doesn't blow out my welds.

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Then you clean and weld. I welded the harness bar to the main hoop on the welding bench.

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Then put the main hoop back in the car.

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Then after throughly tacking the rear bars, I tilted it all back.  I had designed this into the cage, where the rear bars hit an existing bar, I made it so I could pick it all up and slide it back to drop the rear bars down some.

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Now I could weld the top of the rear bar to main hoop joint.

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Then roll it back into place and tack it all back down.  Including the rear bars under the car behind the rearend.  This is going to be fun to fully weld.

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The I tacked the door bars back in.  Just 8 more joints to weld.  Then close of the holes in the floor, fit the carpet and re-assemble the rest of the car.

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mstrpth likes this

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I finished up the crown vic a couple weeks ago.  Here are the finishing details.  I had aluminum plates cut to cover the openings in the floor where the cage passed through and I picked up some straight and pre-formed 1" hose to connect the breathers to the valve covers.  There were lots of other little things, but I didn't take tons of pictures.

 

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Disney and JohnC like this

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