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Thread: Cegan builds a roll cage

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  1. #1 Default Cegan builds a roll cage 
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    So dad bought a new daily driver, and said that he wanted to race his old Saab as a family race car. So here we go.

    The car is a 2008 Saab 9-5 Aero wagon with 254k miles and an original clutch. So what could go wrong? Started by stripping it out in preparation for the cage.





    The car is covered in sound deadening, I don't care enough to take it all out, but it needs to come out where I'll weld in spreader plates. So, the best way to pull it seems to be freeze it. Mix some isopropyl alcohol with dry ice pellets to make a slurry. then spread on the sound deadening and let it sit. The material will separate from the floor and become brittle and peel up in larger pieces. On older cars the material will come up almost entirely in one sheet since it's dried up more, but this is new enough that it's still a little soft in it's normal state.





    Tonight I bent up the main hoop. First time ever touching a tube bender, so lets go for a hard part.






    Tomorrow I'll trim the extra off the legs, pull the front seats, and make sure it fits. It fit the roof perfectly after the first two bends, but it was too late to trim and fit after the second two.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
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  2. #2 Default  
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    Will the cage be extending into the hatch area, or is it just going to be the front of the car?
    "It was more passionate than just cuddling"
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  3. #3 Default  
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    Quote Originally Posted by splatt View Post
    Will the cage be extending into the hatch area, or is it just going to be the front of the car?
    A little. The rules state that the rear down bars need to terminate no further back than the rear axle. The main hoop sits just in front of the rear seats and the down bars should terminate on the wheel wells.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
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    you are definitely one seriously dedicated, possibly certifiable individual
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  4. #4 Default  
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    Pretending for a second anyone will read this or care, got the main hoop trimmed tonight. Fit is awesome.






    Goal is to bend up the forward bars on thursday, the windshield bar on friday, and weld all those in over the weekend.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
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    you are definitely one seriously dedicated, possibly certifiable individual
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  5. #5 Default  
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    I'm watching. I actually came here hoping you'd get a chance to trim the main hoop and test fit.

    -Justin
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  6. #6 Default  
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    Probably a dumb question, but will you be welding in the main hoop first then welding everything to that, or welding it all together then welding the whole assembly in?
    "It was more passionate than just cuddling"
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  7. #7 Default  
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    Quote Originally Posted by Justin.b View Post
    I'm just surprised their isn't a pre-cut kit for such a common application.

    -Justin
    Common? I doubt many people at all have caged saab wagons. I could have measured and had a kit bent by a race shop, but that takes at least 6 weeks.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
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  8. #8 Default  
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    Quote Originally Posted by cegan09 View Post
    Common? I doubt many people at all have caged saab wagons. I could have measured and had a kit bent by a race shop, but that takes at least 6 weeks.
    I've been having a bad sarcasm week.
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  9. #9 Default  
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    Did the first welds tonight. Tacked the front tubes to the main hoop, and then the windshield bar to the forward bars. Cut some holes in the sills, dropped the cage, and welded all the joints. Also welded in the gusset bars between the forward bars and the windshield bars. Then we pulled it back up and slid some plates under it to hold it.

    I did manage to stand up while climbing into the car and shove my back against the bars I was just welding. Hurt like a mother fucker.



    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
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  10. #10 Default  
    Bravo sir
    Quote Originally Posted by bigben View Post
    You.... have problems.
    Quote Originally Posted by Big Pete View Post
    you have issues.
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  11. #11 Default  
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    Next update: this is now a burn healing thread.
    "It was more passionate than just cuddling"
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  12. #12 Default  
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    Got the cage welded to the spreader plates, and the main hoop lower horizontal and diagonal bars installed.

    Tomorrow I'm working on the car all day. Getting seat installed, harness bar installed, and rear down bars installed.



    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
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  13. #13 Default  
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    Didn't get as much done today as I wanted. Got a late start, and then was asked to help dig a plow truck out of the weeds.

    I got the seat mounted, which took way too long. I can't weld to the seat base because I think it's aluminum (it's not magnetic), so I had to make bolt on brackets, and each corner had to be different. But I got that done and the seat is in the car. I also got one of the rear down tube spreader plates welded in (no picture).

    The car is a complete mess right now. once I'm done with cage stuff I'll be able to go through and put all the wires back in their homes. I've been moving them around to prevent damage from welding slag.




    Dont' worry, the seat isn't cracked, there's just some old masking tape that looks terrible.




    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
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  14. #14 Default  
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    I mean...you CAN weld aluminum to steel. It's just a pain in the ass.

    I know this because I read it on the internet.
    "It was more passionate than just cuddling"
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  15. #15 Default  
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    Quote Originally Posted by splatt View Post
    I mean...you CAN weld aluminum to steel. It's just a pain in the ass.

    I know this because I read it on the internet.
    I do not posses the equipment, or skill.
    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
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  16. #16 Default  
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    Worked on door bars last night. Drivers side are notched and fitted, passenger are bent. I should have the cage done by Thursday night at this rate.



    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  17. #17 Default  
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    Got the passenger door bars all notched and fitted tonight. Also got the harness bar fitted and notched. All of those are ready to weld in tomorrow night.







    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  18. #18 Default  
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    The cage is (99%) done. All of the bars are in. I have a few gussets to add to the door bars, but otherwise it's done. I don't have a great picture of the completed thing, but at least you can see the down bars that were added last.




    I also started re-fitting the dash last night. And by re-fitting I mean hacking it up. I'm not sure if I saw a glimpse of regret on Dad's face as I took a saw to the dash for the first time. It's pretty close to fitting, just needs a trim here and there.

    Futility Motorsport - 1989 Dodge Daytona Shelby (dead), Saab 9-5 Aero Wagon, BMW 313rx
    Quote Originally Posted by buzztt View Post
    you are definitely one seriously dedicated, possibly certifiable individual
    Motorcycles - KZ400 Cafe Build, XS500 Build
    Reply With Quote  

  19. #19 Default  
    i wish i knew how to do these things, looks good!
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  20. #20 Default  
    ^^ what he said. Cage turned out great. I'm impressed
    Bath salts and dick pills
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