Installing a roll bar on an already painted car?

[fleiss75]

Anyone have any advice..tricks to getting everything right the first time? A special hole saw that works best? I am looking for every bit of good advice so this can be done right the first time.
Thank you

[Double Venom]

fleiss75,

Show us a photo of the roll bar area, and the roll bar-assembled off the car. ?
(Not familiar with your car or the type of roll bar 'it' uses.)

DV

[mickmate]

Start with checking your location about a dozen times from above and below the body work. Put the masking tape to the paint and if you can use a holesaw from both sides in the same centrehole that will do it. The edges usually get a grommet or trim plate over them so it doesn't have to be perfect but does need to be as close as you can get it. I have a set of rollbar installation instructions in Word I can send you if you shoot me an e-mail to streetcobra@roadrunner.com .

[Tommy]

One technique to minimize chipping and splintering when cutting fiberglass with a hole saw is to run it backwards. Steady pressure will cut the hole, but with it turning backwards the teeth will not dig in like they do when turning forward.

[YerDugliness]

Great tip, Tommy!!!

Cheers from Dugly

[Blas]

Before you start the installation of your rollbar, you might want to consider the negative aspects of having a steel bar located just behind your head. While I am aware of the total lack of any support from the windshield in the event of a roll-over accident, (say goodnight Gracie) I would also consider the interaction of the rollbar and the back of your head in the event of a non roll-over type accident, which would be much more common occurance than a roll over. A simple minor rear end collision could prove quite devastating to the back of your head, and any side collision could also do the same damage to your noggin....At minimum, a good pad of some type would be a great idea on the bar...And we are not talking about the hot water pipe insulation foam that I have seen on a few peoples cars either....Check my gallary for an example. (Good design but not perfect)
Just some food for thought...I have a Superformance Rollbar Installation instruction guide if you need - for a passenger side installation, but good reading...send me a email address if you want a copy.

[vettestr]

A couple of install hints for painted areas ..... use fender covers or similar to protect general working area for that dropped chuck key etc.. drill small pilot hole in center of any hole to be cut.... a common laser line and pointer can be used to verify or prove before cutting and also through the small pilot hole. Hole saws on curved body parts can make larger diameter holes so be careful, I always use a smaller hole saw and enlarge to finish diameter with a high speed burr. Last but not least I use tools/drills from the non painted side when possible to reduce paint nicks. Always run burr from non paint side so it can't skid or walk across paint area. Measure often.

[BT SNAKE]

This may or may not work for you but it's the way I did it. First I bought some plastic pipe same diameter as my rollbar. I measured up from the mounting location to the underside of the body. Then you cut a piece of the plastic pipe to the measured length. Stick that in the mounting hole and
trace around the circumference of the pipe. Find the center of the trace and cut the hole. Make sure you put tape on the paint side. Use a fine tooth hole saw. Do the the same for the other rollbar leg. Mount that part of the rollbar then measure for the down tube and mark where it contacts the body. You may need to cut another piece of plastic to fit the inside as well. Drill a tiny hole where it meets the body. To see if this was fairly straight I tied a string to the down tube mount and up through the holemto where it mounts to the back of the rollbar. If this looks good to you then cut the hole. Generally this hole will need to be filed oblong as the upright bar passes though at an angle. I filed mine with a die grinder.
This might seem to be a lot of trouble but it worked for me.

Hersh

[fleiss75]

The roll bar is from Shell Valley, I will take a picture of the area tomorrow and post.
Thank you for all the help.

[mdross1]

Whatever method you use it's Okay to be uptight,I certainly was during my installation.The uprights are the easy part,if you use the back support bar it is pretty much done the same way making checking and rechecking measurements.I used the mounts and short pieces of pipe to get the hole locations from the underside of the body.Then finished sized the holes with burrs,the grommets give the finishing touch.Good Luck

[fleiss75]

Success! The roll bar is in and it looks great, it was one of the scariest things I ever did and watched but all the planning and extra measure paid off! Measured 300 times and cut once! Thank you to everyone for all the help and suggestions!

[imfastrnu2]

lol! Man I was super nervous putting mine in BEFORE it was painted! I'd be a nervous wreck after it was! Congrats on the install.

[fleiss75]

It was absolutely terrifying...when they started to cut, I had to run out of the shop...cover my eyes and my ears...At one point they screamed oh no..just to see me come running back in freaking out....

[imfastrnu2]

Man! That ain't right!

[fleiss75]

No, but me being nervous made everyone else nervous, and we double checked, triple checks, make mock ups, etc so the fear made us extra careful. Down to seat belts, the trunk latch and the fire extinguisher and IM DONE!