Roll cage preparation.
The single most important feature of a rally car is it’s roll cage. Safety, reliability, and strength will be gained. Expect to spend at least $2500 in steel and labor for a basic 10 point roll cage. If you get quotes above that, start questioning what extra items will be added, such as sound proofing material removal, seam welding, etc. “10 point” means that the cage is tied to the car in 10 locations. The front strut towers (2), the floor of the A pillar (4), the floor under the main hoop (6), the C pillar or trunk (8), and the rear strut towers (10).
With cost in mind there is no need to remove all of the sound material for your first rally car. Down the road should you deem it necessary you can always clean out more. Seam welding is also very helpful for the cars longevity, but can add thousands to our budget. We will be seam welding some key points on the Neon and the front of the car to the firewall, but not much else.
If our goal was to compete in a spec racing series we would send the car out for an acid dip and seam weld the entire chassis on a rotisserie. In this case our goal is to get Kevin and Jake out there and experience rally for the first time in a safe and reliable car, not shave seconds off their established stage times.
We have started by clearing away sections of paint and material and plating the areas of the chassis that will accept the roll bar tubing. This spreads the force from the cage should a roll occur. The next step is to start with the main hoop and the rear of the car. Once seats arrive we’ll carefully adjust the cage to fit the seats and the occupants.
Be sure to check out the gallery for pictures of the progress.