Porsche Boxster roll bar

[scampbel98]

Well I bit the bullet. Ive got a used 2000 Booster roll bar on the way.
At 48" and me 6' 4" its going to be interesting to see what's needed to fit it in.
Anyone done this yet?

[Daniel]

your going to need to modify it to work you may of been better off going with a auto power roll bar.

[ga.spyder]

That will be an interesting project.Keep us updated with lots of pics.I am anxious to see your results.

[scampbel98]

Here's an update. Forgot to take before pics.. so I stole from the eBay auction I won. Hopefully it'll all work out.
The unit was pretty cheap (too cheap in fact - the seller had marked it "free shipping" and we had to renegotiate a bit later )



It wouldn't fit direct. the PRB is just too darn wide - but ooooooh so close. So first thing - I popped the middle trim and chopped it with a sawzall in the middle - a bit off center. As it turns out, there's already a reinforcing bar inside. This thing effectively doubles the thickness and actually floats inside. Next I mounted the two halves and figure out how much I actually needed to thin out the middle overall it was about 4-5 inches (i'll measure later). Next I ground off the side reinforcements, shortened the front legs about 2" and ground off the front and rear plate (for reuse). the back legs were cut off and rotate and swapped side to side. I then spent a good amount of time shaving the legs to meet the curvature of the fitment points. (work in progress)

I'll shoot more pics of the cuts, etc later... It's just a loose fit to finish mock up and tackweld and then stick weld.. I think I like it.

[spiderrey]

interersting

[v6spider]

Looking good... when your done powder coat it.. just a suggestion...

Rob

[ga.spyder]

I like the looks of the bar in the car.Really nice work on making it fit! Congrats.

[csi2000s]

I'm looking to do the same. Do you have anymore pictures?

[Daniel]

Nice work! looks good in there too...

[scampbel98]

more pics to follow. have pulled the test-fitment out to fully weld up.
One of you guys asked for details. resend me the PM and i'll work up cuts/sizes etc...

[scampbel98]

Here's some more pics.
The "support" bar floats between the cross bar until welded


Image of the remaining "support" bar. it was one full piece, mirrored ends and press fit.


Lower portion (3 pieces) is what was cut from middle


When you cut the middle your final cuts should have a couple of degrees of angle to make up for the bow naturally in the middle section. See the pics for the small gap I need to grind away.

I cut the rear legs loose, rotate them (yeah I know and then knocked a an inch or two off to get the height right.
Then used a grinder to adjust the angles where the legs hit the car. Doing all this with the two major halves made it easier.

I ground off the lower mounting lugs for reuse. I played a bunch with rotating them to get them aligned to where I can do bolts.

http://i776.photobucket.com/albums/yy47 ... 4332fa.jpg

http://i776.photobucket.com/albums/yy47 ... ab849a.jpg

http://i776.photobucket.com/albums/yy47 ... 01d4fd.jpg

http://i776.photobucket.com/albums/yy47 ... fbc3db.jpg

http://i776.photobucket.com/albums/yy47 ... bc5e76.jpg

[scampbel98]

just thinking now that i'm looking at it and knowing what i'm know now..

A steady hand could likely grind away the outer center section weld and just split the two halves thereby saving the internal brace for reuse - you'll have to cut some off of one end as they're tapered but would give more support.