1 It all starts with the base for the main hoop. Tim Christ of CCD is going to use a piec
This month’s story about the fabrication of a custom rollcage for our Project Unfair Camaro (from Prodigy Customs and II Much Fabrication) comes from a new location. Coast Chassis Design (CCD) is a chassis shop located in Daytona Beach, about 40 miles from the author’s shop. John Parsons and Frank Serafine of Prodigy Customs opted to have the folks at Coast Chassis do the rollcage from scratch rather than do it themselves or buy a rollcage kit. We’ll let John explain why.Jim Campisano
Frank and I have been asked numerous times why we decided to have CCD build and install our rollcage. We’ve both installed cages before, both separately and working together. And that’s the point. We know our limitations, which include our tools and the inevitable compromises of a kit. We also wanted to keep the cage as light as possible and that means using 4130 steel (often called chromoly). Indeed, 4130 is about 30 percent stronger than ordinary mild steel, which means you can use thinner wall tube, reducing weight. However, welding 4130 requires high-quality tube fits with zero gaps so the welds can be kept small to minimize the HAZ (heat-affected zone). See the sidebar on page 110 for more on properly welding 4130.
2 CCD likes to use "Illustration Board," available at your local fine arts store, for tem
So with all that in mind, we approached Coast Chassis Design to see if it would be interested in building a rollcage for Unfair that satisfied both NHRA and NASA (road racing) requirements. We met with Pete Bonafide and Tim Christ (co-owners of CCD) to see if they were interested.
All it took was to have a look around at their unbelievable shop and we were hooked. TIG welders, tube benders, lathes, mills, iron workers, bandsaws, tube notchers, sheetmetal brakes, and bead rollers were all on full display. The shop was spotless, and several chassis were in various stages of completion. In the middle of the shop was their latest 10.5 tire/6-second bad-boy Mercedes AMG featuring a full-tube chassis, Funny Car engine, and more tricks than Madonna. Pete and Tim were intrigued by our 8-second drag strip requirement, along with streetability and our road-racing goals. They’ve built many cages over the years, and ours was a simple one in their book.
3 After transferring the template from the illustration board, Pete Bonafide uses a massi
Speaking of books, the first thing to decide about the cage is the proper diameter and wall thickness of the tube itself. The NHRA requires 1 5/8-inch tube with .083 walls for 4130. NASA’s rulebook has a whole section on tubes and wall thickness, but is oddly silent about 4130 tube for 3,500-lb cars (which is the high-water markUnfair better not weigh more than that). It does allow for 1 3/4 tube and .120 wall for DOM (mild steel) tube. After much consideration and a consult with some NASA rules officialswhich really didn’t helpwe decided to use 1 3/4x.095 4130 tube.
From there, we moved on to the shape and look of the cage. The term rollcage came about because of its obvious requirement to keep the roof of the car from collapsing on the driver in the event of a rollover. While that requirement is important, rollcages also improve the performance of the car, and they do that by stiffening the chassis. Tim takes it a step further. He designs his cages to not just stiffen the overall chassis, but also to provide additional support at all the suspension points. And that means a lot of pointsthe number of tube junctions welded to the floor or frameto the cage. There are 16 in all for Unfair.
Keeping the moving parts down to just what’s supposed to move improves the basic repeatable performance of the car, and allows tuning efforts to focus on things like springs, shocks, and pre-load. If your four-link brackets are moving around as you launch at the strip, or the front subframe is twisting instead of the front springs compressing, it’s hard to have consistent responses when you change the springs or adjust the linkage bars.
4 A belt sander readies the cap for welding.
5 Tim TIG welds the end cap into place, and it is now ready for the main hoop.
6 Not a bad weld, eh? Tim is one of the best TIG welders we've ever seen.