Here is a step by step to fabricating an Eleanor roll bar for a '67-'68 Mustang fastback. The rollbar is very similar to the original '67-'68 Shelby roll bar, and it will install in exactly the same way. This roll bar is not NHRA legal, but it does add a margin of safety and it has "The Look".
Our starting point is a 10' long piece of .120" wall 1 3/4" round mild steel tubing:
There will be three bends in the roll bar. The two outer bends will be 86 degrees each, and the middle bend will be 8 degrees. They will all total 180 degrees. The first bend will be made at 28", the middle bend at 53 1/2" and the last bend at 69". All bends are made from one end going left to right, and they are all measured the same way.
The tube is inserted into the bender so the edge of the bender shoe will line up with the mark we made at 28":
The bender is a ratchet style JD Squared unit. The tube is pulled through the bender shoe until the end of the ratchet is reached, the moveable bender arm is moved to another hole, and repeated until the bend is complete. There are three holes that are used from left to right:
The first bend is made until the pointer reads 86 degrees on the degree wheel:
The second bend is made until the pointer reads 8 degrees on the degree wheel:
The third bend is made just like the first until the pointer again reads 86 degrees on the degree wheel:
We now have a roll bar "hoop" that needs to have some tabs welded on:
There are six tabs that will be welded to the roll bar. The two at the left are 2" x 4" x .120" thick plates that will weld to the bottom of each of the rollbar's legs. These plates will bolt or weld to the floor of the car. The two tabs with the rounded ends are 1 1/2" x 5" long and 3/16" thick. They will weld in the middle of each of the outer bends, and will bolt to the roof where the original shoulder harness bolted to. The two small tabs at the bottom are for the shoulder harness of a five point style racing harness:
The roll bar will be clamped into a fixture that locates all the tabs in the proper place:
The bottom plates are clamped into place on the fixture, the roll bar is centered on the fixture, and the plates are welded on:
The two upper tabs that bolt to the roof structure are clamped into place and welded as well:
Finally, the two upper five point harness mounts are clamped on and welded in place:
Here is the finished bar ready to be installed. In the next installment, I'll actually install one in a car: