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8.1. Standard Design
8.1.1.. All diagonals will go to
the top of the driver's side.
8.1.3. Above left shows
the basic design. The less the amount of bend at points ‘a’ and
‘b’ will proportionately increase the strength of the bar. The bend at
‘a’ can effectively be reduced to a straight tube as shown above
right.
8.2. Methods of
Securing Roll Cages to Chassis
8.2.1. In the
following drawings, the rectangle identified as "Chassis" can
also be taken to be an outrigger. The attachment principles are the same.
8.2.2. (Drawing)
8.2.3. The drawing (8.2.2.) shows the
basic principle of a "U"-shaped channel welded over the chassis.
There must be no gaps between the channel and the chassis.
8.2.4. The "saddle"
shown may be an inverted "U" channel, two lengths of angle or
three flat plates. The objective is to spread the load over a large area
of chassis rather than concentrate the loads on a 2" / 50mm (or
thereabouts) diameter spot.
8.2.5. Roll-cages can be made detachable
as shown in the following drawings. The ”U”-shaped saddle is replaced
with lengths of angle and a base-plate is fitted to the roll-cage tube.
The assembly is then bolted as shown.
8.2.6. (Drawing)
8.2.7. Above left:- Bolting
through a floor. The angle iron is welded to the chassis and a spacer /
packing piece will almost certainly be needed to fill the gap.
8.2.8. Above right:-
Cut-away or no floor panel. As before but the plate sits directly on the
chassis and the spacer is not required.
8.2.9. In many of the
foregoing drawings, a packing-piece / spacer is shown fitted between the
floor of the load area and the chassis. Close fitting pieces of metal or
‘Tufnol’ or similar material (but not wood) the same size and shape as
the foot / base-plate must be used to pack the gap between the chassis and
the floor. It may be necessary to taper this packing due to the varying
gap. The aluminium floor will not take the strain imposed by the legs /
feet of the roll-cage.
8.2.10. The base-plate / feet
shall be at least 5" x 5" x ¼" / 125mm x 125mm x 6mm steel
plate. Bolt holes shall have at least 1½ x bolt-diameter edge margin,
i.e. edge of bolt-hole to edge of plate, angle or bracket shall be at
least 1½ times the diameter of the bolt. (See 8.2.13.)
8.2.11. (Drawing)
8.2.12. The use of
flitch plates or webs around the base of the bars and bracing will greatly
increase the strength. All base-plates shall be at least 125mm x 125mm x
6mm / 5" x 5" x ¼" thick mild steel.
8.2.13. Hole edge
margin "m" shown on the sketch at left shall be at least 1½ x
hole diameter. This applies to other brackets and plates.
8.2.14. (Drawing)
8.2.15. Above is a type of
mounting enabling the roll-cage to be removed leaving only the socket in
situ in the vehicle.
8.2.17. Above is a type of
mounting that fills the gap between the chassis and the floor, enabling
the roll-cage to be removed easily. The height of the top plate above
the chassis can be varied to suit the vehicle.
8.3.
Standard Shape Hoop Mounting onto "A"-Frame Cross-Member.
8.3.1. (Drawing)
8.3.2. (Drawing)
8.4. Main Hoop Design and
Installation for Range Rover / Discovery and other Long Wheelbase Station
Wagons.
8.4.1. The following design has
been devised to give access to the rear seats in all long wheelbase
vehicles. It is a "D" hoop mounted on a substantial box-beam.
The methods of attaching the hoop to the beam and the beam to the chassis
are shown in detail. The diagonal can go in either the "a" or
the "b" position. The diagonal and the rear braces can be made
detachable using methods shown later. On a Range Rover, the rear braces
just clear the top of the back seats.
8.4.2.(Drawing)
8.4.3. The design shown above is
for use in Range Rover, Discovery and any other Long Wheelbase
station-wagon vehicles. They give a more stable base due to the extra
width of these vehicles and give back seat accessibility
8.5. Methods of
attaching the hoop to the box-beam
8.5.1. (Drawing)
8.6.
Methods of attaching the box-beam to the chassis.
8.6.1. (Drawing)
8.6.2. On early Range
Rovers, the rear floor can easily be removed and new panelling fitted
round this assembly after installation.
8.6.3. (Drawing)
8.6.4. On Discoveries and later
Range Rovers, the floor panels are welded in. The method shown at left can
be used to mount the box-beam below floor level by cutting the beam by
2" to fit over the chassis. Angles welded at the joints should
adequately restore the area to full strength.
8.6.5. This method is stronger
than reinforcing existing outriggers or adding fabricated ones.
8.6.6. Spreader plates are not
required where the roll-cage tube is welded on to ¼" / 6mm wall
thickness box material.
8.7. Roll-cages on 101" Wheelbase
Forward Control Land Rovers
8.7.1. The major problem with this
vehicle is that the roll-cage needs to straddle the engine making it
impossible to run the requisite diagonal from the top corner of the hoop
down to the chassis in the normal way. This particular vehicle type was
not considered when the original roll-cage regulations were drawn up. The
following design has been passed by the ALRC Council and the Scrutineering
Committee for use on this vehicle type only.
8.7.2. The
outriggers can easily be re-inforced if necessary with the addition of a
6mm / ¼" top plate extending onto the top of the chassis. The cab
can sit on top of this too. There are usually some shims between the cab
feet and the top of the outrigger (typically 3mm / 1/8") but the
addition of the reinforcing plate would raise the rear of the cab by a
maximum of 6mm / ¼". This shouldn’t cause a problem as the cab is
a large unit.
8.7.3. Additional
side plates can be added to the front face of the outrigger. There are
usually some shims (typically 3 to 6mm / 1/8" to 1/4")
between the rear face of the outrigger and the front face of the back body
unit. Building this up to 6mm / ¼" shouldn’t be a problem as, at
worst, the back body will be pushed back by this amount. (maximum)
8.7.4. If the fuel
tank is to be left in its original position, then the petrol filler pipe
will need to be re-routed. The rubber filler hose goes from the filler
point, into the void behind the front seat and then down through the top
surface of the outrigger and then out of the aft face of the outrigger and
into the tank. A new pipe to the tank could easily be made from a
combination of metal pipe and rubber hose. A route similar to the original
could be used or alternatively, it could easily be made to pass downwards
from the aforementioned void to a point ahead of the outrigger and then go
rearwards right through the outrigger and into the tank.
8.7.5. On the
left hand side, the air filter will need to be moved.
8.7.6. The
hoop will be attached to the top of the re-inforced outrigger 55mm / 2¼"
in from the end as the cab mount frame bolts through right at the extreme
outboard end. The hoop will be adequately wide at this position. If
needed, the hoop width could step out to full vehicle width once clear of
the cab structure.
8.7.7. The two
diagonals would go from the upper corner bends to the top of the chassis
giving a base width of 500mm / 20". The left-hand diagonal can now
tuck in under the overhanging manifold and attach to the top of the
chassis.
8.7.8. Details on materials, fixings, welding, mount types,
front-hoops, rear braces, etc. can be found earlier on in this set of
regulations.
8.7.9. The drawing below shows the relevant design and
dimensional details of the hoop.
8.7.10. (Drawing)
Dimensions quoted are for guidance.
8.7.11. The drawing below
shows a plan view of the outrigger.
8.7.12. (Drawing)
8.8.
Diagonal Braces for Main Hoops
8.8.1. (Drawing)
8.8.2. The diagonal shall
touch the base-plate, if only by its tip. See drawing.
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