These photos show our process...
These photos show our process designing and fabricating the roll cage for this 2008 Ferrari F430 Scuderia Track Car.
We’ve never seen another shop go about the process...
We’ve never seen another shop go about the process of designing a cage with string. For us though, this was natural and the best way to identify the miter angles and radius bends for our bending software and bending and notcher machines.
We utilized Chromoly steel tubing...
We utilized Chromoly steel tubing for its higher strength and slight weight savings. We CNC’d custom end fittings and tabs in 4000 series steel for the side impact bars, which had to be removable.
We utilized Chromoly steel tubing...
We utilized Chromoly steel tubing for its higher strength and slight weight savings. We CNC’d custom end fittings and tabs in 4000 series steel for the side impact bars, which had to be removable.
We designed steel cladding to reinforce the Ferrari...
We designed steel cladding to reinforce the Ferrari aluminum rocker frame tube member and a series of cleverly fitted back plates, which inserted inside that tunnel for the cage and cladding to bolt through the aluminum and into the back plate as a sandwich. Our back plates had long, rigid steel wires welded to them so we could fish them through the rocker’s cavity, where they’d stay once cage mounts 1-4 and the cladding were bolted in place.
We designed steel cladding to reinforce the Ferrari...
We designed steel cladding to reinforce the Ferrari aluminum rocker frame tube member and a series of cleverly fitted back plates, which inserted inside that tunnel for the cage and cladding to bolt through the aluminum and into the back plate as a sandwich. Our back plates had long, rigid steel wires welded to them so we could fish them through the rocker’s cavity, where they’d stay once cage mounts 1-4 and the cladding were bolted in place.
Cage mounts 5 and 6 were handled similarly...
Cage mounts 5 and 6 were handled similarly with the OEM aluminum cross brace that ran from left to right on the rear firewall. Back plating was fished through this member and the runners from the cage landed on these firmly. Tabs were welded onto the cage for track staff fire extinguisher pull, extinguisher nozzles, etc.
The Scud’s decorative carbon fiber door panel trims...
The Scud’s decorative carbon fiber door panel trims could not be retained as they interfered with the new side impact bars, so we fabricated new ones with a top section formed in aluminum sheet metal and upholstered in Alcantara with top-stitch detail. The lower section utilized pre-finished CF paneling for an essentially all-flat panel to clear the cage. OEM fastener positions were used and we adapted a Porsche GT3 loop-style door release with a neat little bezel we machined in ABS plastic to finish it all off.
The Scud’s decorative carbon fiber door panel trims...
The Scud’s decorative carbon fiber door panel trims could not be retained as they interfered with the new side impact bars, so we fabricated new ones with a top section formed in aluminum sheet metal and upholstered in Alcantara with top-stitch detail. The lower section utilized pre-finished CF paneling for an essentially all-flat panel to clear the cage. OEM fastener positions were used and we adapted a Porsche GT3 loop-style door release with a neat little bezel we machined in ABS plastic to finish it all off.
A fully plumbed extinguisher was installed...
A fully plumbed extinguisher was installed with nozzles at the front and rear of the cage, engine bay and under dash. Remote releases for fire were at the driver’s window for track staff and at the OEM radio location for the driver, where we made a neat panel to accommodate it and the master battery/electrical shut down slam-button.
Appropriate modifications were made to the seats...
Appropriate modifications were made to the seats and upholstery to accommodate the necessary 6-point Schroth harnesses. A proper harness bar was fabricated and fitted to the underseat for points 5 and 6. Shaft collars were applied to the harness bar horizontal on the cage to separate points 1 and 2. Points 3 and 4 were at the seat’s sides/hinge points with adapters. The cage was painted the matte dark titanium metallic as was the OEM floor of the Scud to give it a very OEM appearance.
Cool Suit system was fitted to the car...
Cool Suit system was fitted to the car. Camera and track race recorder system were integrated with a high degree of finish.