Picture of How to build a Roll Bar
If you have seen my first instructable, you will know that I have built a go kart. Well, I found that when going round corners it flipped very easy and the seat acted as a sort of roll bar to stop it fliping over completely.

This dameged the seat and I thought I would build a roll bar to strengthen up the whole machine and to stop it from damaging the seat when it rolled over.

The roll bar consists of about 4cm by 4cm box section. These are the following tools you will need to build this:

An angle grinder (or hacksaw)
A MIG welder or an ark welder
A drill of some sort (a piller drill is best, although a cordless drill will do fine)
Wire brush (unless you have a wire brush attachment for an angle grinder) 

This roll bar is useless if you haven't already built the go kart.

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Step 1: Making the curve - cutting

Picture of making the curve - cutting
roll bar.bmp
layed out box section.bmp
This step is a really important one - you have to get it right!

To make the curve in the metal, first you have to cut out a small triangle shape in the box section. The pictures show all the measurements needed to cut out the triangle.

There should be 68cm at either end of the box section. When it is all completed, the overall height of the roll bar should be 95 cm, and the width should be 52 cm.

Do not copy the actual pictures as they are not to scale, please copy the measurements written on them. The pictures are only there to give you a rough idea of what it should look like.

Step 2: Making the curve - Bending

Picture of Making the curve - Bending
This step is the easy part. Just bend all of the metal so that all the triangles are closed up. Then the roll bar will start to take shape.

Make sure the gaps are completely filled otherwise the angle will be two big and the bar will not fit on the go kart.

Harbor Freight has a really good pipe bender thats not to bad priced. It comes with several sized forms to handle a wide range of pipes. Truth be told, if you have a bottle jack and some spare pipe, you could make one.... Might make a goood ible!! Also, heat will aid in bending the pipe, red hot, not white hot, and it will prevent the pipe being bent from wrinkling. Keep at it, but be safe..
kosmicride5 years ago
Good work although I would never recommend this being used as a form of protection as each section you welded has weakened the metal. A solid hoop is the best way to go.
DragsterIOW (author)  kosmicride5 years ago
yeh, i kinda thought that as well, but i didn't hav a bending machine, so i had to do this instead.