The safety structure known as the roll cage is the primary safety element in any race car. It is designed to protect the driver in the event of an accident, in particular one that involves the vehicle overturning.

In many vehicles, the roll cage also forms the mainframe structure and is often a compromise between complex stiffness, safety, weight, and cost. Today, we will discuss how you can build a roll cage for a car. So let’s take a look at how to build a roll cage for a car?

What is the roll cage?

  • A roll cage refers to a metal structure (steel tubing) that can be made around the inside of a car.
  • Typically they are used to strengthen the vehicle and make sure that the rider is protected in the case of an accident, mainly if the car rolls.
  • Roll cages are useful for cars that are being applied for racing & stunt work due to the aggressive driving style & the increased danger.
  • They are also ideal for off-road vehicles.

Roll cage designs:

You will find plenty of roll cage designs that appear for use, relying on your needs. The most fundamental and perhaps the best choice for your car is an 8-point roll cage. An 8-point roll cage comes with the following items.

  • A back brace
  • Subframe struts
  • Gussets
  • A windshield brace across the roof
  • A main hoop and
  • Gussets

Besides this, you will find 10, 12, and 14-point roll cage that gives your car more structural integrity.

How to build a roll cage for a car:

Let’s take a look at the step-by-step process of building a roll cage for a car.

What do you need?

  • DOM mild steel tubing (3/4”)
  • Tube Notcher
  • Tube bender
  • Tape measure
  • Brace
  • Metal pipe cutter
  • Hand grinder
  • MIG or TIG welder

You need to ensure that you have enough space to install the roll cage before you start building. You may need to remove the carpet and seats of your car.

Step to follow to make a roll cage for a car:

Step 1 (Measuring):

It would be best if you took the time to make sure that your measurements are perfect. Taking accurate measurements will let you know the ideal length of the tube you need. Don’t forget to record the following measures:

  • Height of ceiling to the floor
  • Measure from the back of the seats to the first firewall
  • Width of the inside

Step 2 (The base plates):

It is recommended to have larger base plates, which will make sure that the legs are strong when attached. The backplates need to sit behind the front seats while positioning the plates.

Also, you need to set up the head ones at the front of the firewall. When it comes to fitting the base plates with the ribs on your car floor, you may need to bend it to make sure they are secure.

Step 3 (The main hoop):

The main hoop is a solid piece of tube that is bent into a U shape. This U shape tube is then welded to the back baseplates with two ninety-degree bends at the ceiling of the vehicle.

Step 4 (Supporting bar):

The use of a tubing notcher If you want to make the edge of the supporting bar set into place, the use of tubing notcher could be the right choice.

It would be best if you welded the edge of the supporting bar at the front base plates. On the other hand, you need to be welded into the main hoop as well.

Step 5 (Welding):

It would be best if you needed an excellent, confident level in welding your roll cage. Make sure that you set up all the bars in the perfect position.

Now weld around the attachments while you feel 100% confident with their positioning. You need to ensure that your welding quality is standard enough to make the roll cage secure.

Step 6 (Bracing):

A right piece of the tube needs to set up above the shoulders of the driver and at the inside of the main hoop.

The bracing will work as a secure spot for shoulder belts. Besides, to get extra protection for both driver and car, you can set up tubing on the doors.

Frequently Asked Questions (FAQ):

1. Can I put a roll cage in my car?

Simply putting a roll cage can cause a severe head injury. But when it comes to race cars placing a roll cage plays a significant role.

The racing cars could be crashed over high speeds; therefore, they need to add enough hardness to the body armor with a roll cage.    

2. How much does a roll cage for a car cost?

You usually need to spend USD 2,500 to USD 4,000 for a custom roll cage and seat mounts.

3. Do roll cages have to be TIG welded?

TIG welding is not necessary for all roll cages. But if you talk about a sports car, then the TIG welding is essential to have for safety issues.

4. At what point do you need a roll cage?

Having a roll cage is compulsory for any car that can exceed 135 MPH within 11 seconds. Here the irregularity is if your vehicle keeps an unchanged firewall, body, and floor without exceeding a 10-second, in what you a roll cage may go.

5. Do roll cages help in a crash?

The roll cages are designed to protect your car from crashing. It stops the owner portion from being damaged during a collision or a perfect rollover or two.

Final Words:

There you have the guide how to build a roll cage for a car. However, it seems to be a great project for making a roll cage for a personal car. But if you do not feel confident enough while welding, you should leave the project to a professional one.

The main goal of a roll cage is safety. On the other hand, a roll cage with bad welding is not safe for use.

Thanks for staying with us. Do you feel that we have any mistakes? Or do you think we need any update in our article section? Please share your thoughts and feel free to leave a comment below.


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