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Old 01-02-2012, 08:30 PM
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Default 996 Roll Cage Work

One of my good buddies has a local fab shop. He can pretty much weld anything, but his speciality is putting roll cages into various Porsches. He's a mad man and a fantastic fabricator.

Anywho, here are some pictures from a recent GT3 996. Customer wanted the cage tight to the chassis, but not overly obtrusive in vision. This seems to work. It's not over the top, but still a quality piece.

Shameless plug: If you guys know anyone in Northeast USA that wants a nice cage, or any fab work just send them to JPC Fabrication























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Old 01-02-2012, 08:31 PM
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And to those curious to the sideways supertrap's on the exhaust, that's how you pass the noise level requirements at LimeRock.
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Old 01-02-2012, 08:38 PM
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Nice looking cage. I like the fitment. I see so many cages that are like a foot away from the chassis or have an a-pillar bar that comes down 18" from the firewall.
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Old 01-02-2012, 08:51 PM
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That's the fitment I'm hoping to achieve as my cage progresses. Takes so much more time to make sure all of the measurements are exact and the bends are perfect to the degree. So worth it in the long run though.
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Old 01-03-2012, 09:31 AM
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Quote:
Originally Posted by Def View Post
Nice looking cage. I like the fitment. I see so many cages that are like a foot away from the chassis or have an a-pillar bar that comes down 18" from the firewall.
I forgot what classing the cars are in, but I know that there is a rule about not being able to weld the chassis to the cage persay, aside from the mounting points.

On this yellow for example the guy wanted the cage to touch the chassis, so he did it (don't mind the paitners tape we got it out). I persoanlly would be worried about vibration noise from it, but they say there is none:








Now the Cayman cages are a little different. They can't follow the door pillar exact or you'd have a wierd bend in them. There is still a ton of room though.





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Old 01-03-2012, 09:45 AM
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I'd be scared of the door bars on the Cayman from punching through my kidneys in a wreck.. That's one helluva bend there..

I saw one cage done by my local guy where they put the main hoop and A pillar bars in, then used a porta-power to mash them out to the chassis before putting the rest of the horizontal braces in. He said when they were on a rough track, the cage would squeak against the chassis...

another trick he did for Showroom Stock cars (no chassis bracing allowed) was to build the cage over some of the factory seat belt holes and such. then they drilled holes in the cage, ran bolts through into those mounts, cut the heads off the bolts and TIG'd them to the cage. then they ground it smooth, a touch of bondo to get rid of grinding marks, and the bolts completely disappeared when they painted the cage. After they put the trim back in the car, nobody was the wiser. voila!
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Old 01-03-2012, 10:33 AM
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Yea, I'm not a huge NASCAR door bar fan unless they have the downward bars that are in compression on a hit holding the bent bar out. If you leave those out, it's not very strong at all even though it weighs a ton.

The best cheap way I've seen to do door bars is take two bars and bend them out into the door a few inches making an uninterrupted X and weld them together then put a gusset on both sides. Basically you have a bent X that is as thick as two bars in the middle. In a hit it will force the main hoop and a-pillar bar to spread, taking a ton of energy in the process.
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Old 01-03-2012, 10:42 AM
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Nice work, I'll be in the market for a 4 point cage at some point in the next few years but probably something more budget oriented.

GT3...sigh. Wish there was a GT3 style Cayman, that'd be cool.
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Old 01-03-2012, 12:02 PM
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Nice work, I'll be in the market for a 4 point cage at some point in the next few years but probably something more budget oriented.

GT3...sigh. Wish there was a GT3 style Cayman, that'd be cool.
Then who would buy a regular 911 to do trackdays?

Actually I hear Porsche is kicking themselves a bit since the Cayman is cannibalizing more 911 sales than they expected.
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Old 01-03-2012, 12:09 PM
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I totally understand what you mean with the tubes being welded to the rocker panel, but again these are examples were some of the ruling doesn't allow for attachment of the cage to the chassis in places like that. On the normal cars he actually continues the verticle tubes down to the rockers. It's crazy the amount of rulebooks and regulation regarding cage stuff across the many different sanctioning bodies and run groups...perplexing that there isn't a 'standard' yet.

I do know though that while those bars are not perfect, they do work. The first Cayman he ever did got wild up through the bus-stop at the Glen and collided with the wall...the bars worked just as intended by helping bounce the car a little. Driver never even had the bars touch him.

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Actually I hear Porsche is kicking themselves a bit since the Cayman is cannibalizing more 911 sales than they expected.
It's gotta be true, as Jay has done a considerable amount more Caymans this year/last year than 911's...can't blame guys as they are a great little car.
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