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In the Workshop - Rollcage Modification

 

The roll cage fitted to the Rav has not changed since the car was built. Although MSA and FFSA approved and log booked, and having been *tested* a number of times, both the AWDC and SCOR said it did not meet current racing regulations and needed to be modified to allow the car to race in 2025.

 

Previously, the Rav has no bracing in the roof at all. This was OK 'back in the day' but the 2025 regualtions section 56.13.2 states :

"a center roof bar much be installed either diagonally or, evenly spaced in line with the exterior longitudinal bars, as shown in K Appendix 2, drawing 53. If more than one centre bar is fitted, the bars must be evenly spaced. Double crossed roof bars, to the minimum specification for optional members, are strongly recommended, as shown in K Appendix 2, drawing 10."

 

 

I asked the club scrutineers for advice, and they put me in touch with Barry at Dodds 4x4 in Ferndown, Dorset. Barry was really helpful and after some discussion we worked out a plan to add a cross to the roof of the cage. 

 

First step was to check clearances. I mocked up the cross using some plastic waste pipe. With this I was able to check that our helmets will clear the padded cage OK. 

 

 

 

Welding the tube to the existing cage looked possible. A bit tight at the front by the windscreen, but the main issue was going to be welding around the tubes in the middle of the 'X'. Fortunately the Rav once had a removeable sunroof. This has been sealed a riveted shut, but with a bit of work this could be removed to access new cage intersection from the top and weld it together.

 

First step was to drill out all the rivets that hold the corner plates to the sunroof panel, then to unstick the seal and prize the roof open. This would give the access needed. This was the first time this view has been seen for 20 years...

 

 

The car was delivered to Dodds 4x4 on the Friday morning and the car was ready to collect just after lunch the followind day, now with CDS cross welded into cage :

 

 

A clean up and a bit of paint :

 

 

And a view with the car reassembled and new padding (mainly to stop helmet scrapes when getting in and out!) fitted to the cage :

 

 

Next step, scrutineering...