E30 Weld-it-yourself- DIY Roll Bar kit installation instructions - K5001-K5006

Welding instructions for your DIY roll bar kit

Disclaimer: These should be welded by a certified welder who has experience in welding safety equipment like roll cages. Garagistic is not liable for injuries. This is a roll bar, not a roll cage and is not certified to achieve anything in the case of an accident or injury.

What you will need:

- Mig welder (tig is also acceptable) 

- Experienced welder

- Acetone

- 12mm Drill bits

-Cut off wheel (or or portaband)

What is in the kit?

All roll bars come pre-notched to only fit one way. No modifications of any kind are required except for cutting down rear legs and main hoop. The main hoop and the rear legs are left 2-3" long and will require being cut down to your liking. Comes with mounting plates and hardware as well.

Why is main hoop and rear legs left long?

The main hoop and rear legs are left longer so that you can cut them down to your liking. If you want the main hoop really close to the roof (or you have a non-sunroof e30), you might want to leave them a little longer. If you want the ability to remove the roll bar in the future easier, you would also have that ability since you cut the legs to your liking. Once you cut the main hoop, you can then do the same for the rear legs to adjust angle, position and landing areas.

Steps:

Step 1: Gut your interior, Acetone all roll bar components to ensure clean work and penetration of welds. Practice correct welding penetration tips by grinding all ends of be clean so welds have good penetration.

Step 2: Measure main hoop height. Then cut hope while still leaving extra. Mock up in car, then measure and cut off bottom of main hope legs until you have found where you leg the roof to main hoop clearance.

Step 3: Tack all the inside components (the harness bar, diagonal bar, etc). Also tack mounting point legs on bottom of main hoop. 

Step 4: If you selected bent rear legs (or straight legs with no rear X), Place back in car and measure where you want rear legs to land. Mark them, cut (still leaving a little extra) then put back into car until preferred landing position is achieved. Tack rear legs.

Step 5: If you selected X in the rear. Tack X pieces to rear legs then tack to main hoop.  Place back in car and measure where you want rear legs to land (this must be done after you have tacked the X pieces to the rear legs. Mark the rear legs, cut (still leaving a little extra) then put back into car until preferred landing position is achieved. Tack rear legs.

Step 5: Weld everything outside of car.

Below is all the possible configurations and how they come together:

Below is the video for: Straight legs + Straight harness bar + No X in the rear (K5005-DIY). If you would like a PDF print out of this configuration click here.

Straight legs + Straight harness bar + X in the rear:(K5006-DIY). If you would like a PDF print out of this configuration click here.

 

Straight legs + Bent harness bar + No X in the rear: (K5002-DIY). If you would like a PDF print out of this configuration click here.

 

Straight legs + Bent harness bar + X in the rear: (K5003-DIY).  If you would like a PDF print out of this configuration click here.

 

Bent rear legs + Bent harness (K5001-DIY).  If you would like a PDF print out of this configuration click here.

 

Bent rear legs + Straight harness bar - (K5004-DIY).  If you would like a PDF print out of this configuration click here.