CAD Modeling and Bending: We use programmable, numeric-controlled rotary-draw benders, for high bend quality and accuracy.
Precision Tube Notching: Tubes are then precision-notched using templates that we have created specifically for our E30 roll bars and cages. These templates, along with our production-quality, indexable tube notcher, allow us to fit the tubes together with accurate and repeatable results.
Structural mounting plates and "plinth boxes" - A Hanksville Exclusive!: We're not fans of the typical method of bolting-in a removeable roll bar - "sandwiching" the floor between plates - which relies on the thin, weakened, 20+ year-old floor and wheelwells for support. For our removeable roll bars, we build our main hoop mounting plates the same way as for our competition roll cages - by fabricating "plinth boxes" that tie the roll bar into the car's rocker panels. This is a time-consuming process, but results in a stronger roll bar with less risk of "punching-through" the floor.
We use the same logic for our rear brace mounting plates. Rather than rely on the wheelwells, we attach our rear braces to the rear bulkhead, just beneath the factory seat belt mounts.
All of our removeable roll bars use boxes made from a combination of 1/8", 3/16" and 1/4" sheet. The 1/4" base plates are threaded to allow the 3/16" main hoop and rear brace mounting plates to attach via 3/8" grade 8 hardware. The mounting boxes and plates are CAD-designed and waterjet-cut for great fit and easy welding.
We know of no other mail-order roll bar manufacturer that goes to this extent to structurally attach your removeable roll bar!
Custom-fitted harness bars - Another Hanksville exclusive!: In the event of a crash, an ill-fitting harness bar may increase the chances of severe injury. Why risk your safety just because other roll bar manufacturers won't customize their harness bar to your individual shoulder height? Measure the distance from the floor to the top of your shoulders, and tell us if you use a head-and-neck restraint. We will custom-fit your harness bars to the height that you specifiy, giving you an added degree of safety at no additional charge.
We know of no other mail-order roll bar manufacturer that will customize your harness bar to increase your safety!
Optional bars: To keep costs low, the basic design does not include triangulation gussets or other optional bars. However, optional bars are available to further strengthen your roll bar or cage, and can be added when ordering your E30 roll bar. Optional bars include rear brace X-bars and triangulation gussets. While these bars add some weight and cost, they can significantly strengthen the roll bar and chassis structure. We work with customers to determine which optional bars might best fit their specific needs and budget. If you have an idea for an optional bar that is not listed here, please feel free to ask!
Test-Fitting: Our mail-order roll bars and cages are test-fitted using specially-designed jigs, allowing us to check the fitment of each bar before shipping to the customer. All of our mail-order cages and bars meet the same exacting standards as our custom-fitted cages.
Labels and Instructions: Roll bar and cage components are labeled and ship with a complete set of instructions, making it easy for the customer to fit the cage in their own car.
Ready-to-Weld: All of our roll bar and cage assemblies are pre-notched and test-fitted, ready to weld with little or no trimming required by the installer.