How to fab or buy crimped galvanized hoop set tubing - Defender Source
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  #1  
Old May 10th, 2016, 06:07 PM
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Dan Pollock
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How to fab or buy crimped galvanized hoop set tubing

Hey folks, I've got a soft top, 3 door 110 with the Exmoor top and hoop set.

This week, I finally finished the install of a roll bar to regain my shoulder belt ability. I COULD bend the forward horizontal hoop bar around the roll bar, but that's ineligent, and the roll bar actually has tabs to accept these crimped galvanized tubes.

I'd like to go from the one long roll hoop bar, to two shorter ones that go from the B pillar bar, to the roll bar, and then the roll bar, to the C pillar bar.

This is the precise setup I'm looking for:



So the question is:
  1. Does anyone know where to buy custom lengths of crimped galvanized tubing?

    OR
  2. Does anyone have advice on how to crimp your own tubing?

Since I'm going to remove the 2-3" distance of the width of the roll bar, I could probably actually make the two lengths from the existing hoop but cutting and crimping, but I'd love advice on how best to pull this off without making something TOO janky.

Thanks!
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  #2  
Old May 12th, 2016, 03:52 AM
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  #3  
Old May 12th, 2016, 08:05 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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I just cut my long pieces with a hack saw then flattened in a vise and drilled a hole.

I have the exact setup pictured above and it looks perfect.

I hit the cut bar with cold galvanizing spray



Edit: I didn't like shoulder belts so I also cut off the roll bar belt attachment points. I then Installed lap belts and had the ability to leave the roll Bar on when my hardtop truck cap was in place
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  #4  
Old May 14th, 2016, 07:25 PM
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Keith Armstrong
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I think I'd squish the flat bits in the vise...but between some wood blocks just to limit damage to galvy surface. If you wanted to get fancy you could rout (e?) a channel in the wood so they'd all end up the same.
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Old May 24th, 2016, 08:25 AM
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Dan Pollock
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Quote:
Originally Posted by Naplm00 View Post
I just cut my long pieces with a hack saw then flattened in a vise and drilled a hole. I have the exact setup pictured above and it looks perfect. I hit the cut bar with cold galvanizing spray Edit: I didn't like shoulder belts so I also cut off the roll bar belt attachment points. I then Installed lap belts and had the ability to leave the roll Bar on when my hardtop truck cap was in place
Giving this a go tonight. Got the pieces cut, but my vice is just too shitty. Heading to a buddy's with a normal, old school big ole vice.

Any advice on how to somewhat match the offset of the factory ends?
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  #6  
Old May 24th, 2016, 08:32 AM
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Bill Adams
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Those things are smushed in a large hydraulic press that whacks 'em in a die that holds the pipe shape. Just flattening the end in a vise won't give you the same result, but it will give you a result.
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  #7  
Old May 24th, 2016, 09:03 AM
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Dan Pollock
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Quote:
Originally Posted by o2batsea View Post
Those things are smushed in a large hydraulic press that whacks 'em in a die that holds the pipe shape. Just flattening the end in a vise won't give you the same result, but it will give you a result.
yeah, that'll just have to do until I can source some factory made pieces
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  #8  
Old May 24th, 2016, 09:06 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Quote:
Originally Posted by DPdotCOM View Post
Giving this a go tonight. Got the pieces cut, but my vice is just too shitty. Heading to a buddy's with a normal, old school big ole vice.

Any advice on how to somewhat match the offset of the factory ends?
Just stick a flat piece of scrap on the side that you want offset the squish away.

It works but obviously isn't for purists
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  #9  
Old May 24th, 2016, 09:29 AM
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Buy a few Legnths of 1" conduit from home depot and crimp (vice) a few ends until you are happy with the result. Much cheaper than potentially ruining the nice factory bars.
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  #10  
Old May 24th, 2016, 10:13 AM
Naplm00
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Matthew
1983 110 200tdi 3 door soft top
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Quote:
Originally Posted by JohnsD90 View Post
Buy a few Legnths of 1" conduit from home depot and crimp (vice) a few ends until you are happy with the result. Much cheaper than potentially ruining the nice factory bars.
Not a bad idea actually
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  #11  
Old May 24th, 2016, 10:18 AM
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Quote:
Originally Posted by Naplm00 View Post
Not a bad idea actually
I made these exact pieces for my 88" hoopset using conduit. I could have done a better job, but you never see the pieces anyway when you have a top on.
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  #12  
Old May 26th, 2016, 12:22 AM
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Dan Pollock
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I'll post pics soon, but in the end, I chopped the piece down to two correct lengths, then cut a notch into the still round end that perfectly slips onto the roll bar tab. Drilling holes in them this weekend to slide a bolt through, but on first pass they fit perfectly and are snug just with pressure (and a zip tie for peace of mind).
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