starletezy Posted December 29, 2015 Share Posted December 29, 2015 (edited) So I have seen a lot of people asking how do you fit an Cusco non sun roof roll cage into an sun roof model and is it a lot of work well I hope I can answer that question for you guys it does take a lot of work and wouldn't recommend doing it your self if you don't have any fabrication skills. all four rear pillars will need to be cut two inches to bring the cage down the reason being the sun roof tray intrudes the cockpit by around two inches the tray wont come out due to being welded and bonded on so the only option is to cut and weld the roll cage. The two front pillars don't need to be cut it just about clears the sun roof motor I have put together some step by step images on how to modify the cage below As you can see pictures the B pillar section of the cage wont fit as the tray above is in the way The bottom of the B pillar post needs to be brought down by 2 inches once the bottoms have been cut off the cage will need to be put back in the car to be mocked up just incase any changes are needed once the cage is in an mocked up and sits nicely take it out and tack weld the bottoms back on Bottoms tack welded on The run roof motor clearance is just about so no modification needed The clearance on top rear B pillar post should look like this So now on to the rear posts as the B pillar posts were brought down 2 inches they will need to come down as well As you can see there way off! If you have a 7 point cage like mine the cross bar wont need cutting thankfully Once you have everything tacked on and lined up weld all four posts up properly I would recommend taking it to a professional welder Edited May 15, 2016 by starletezy Quote Link to post Share on other sites
5e colin Posted December 29, 2015 Share Posted December 29, 2015 your not reinforcing the chassi where the cage bolts down ??? the way its now the cage is just for show and has no safety feature really Quote Link to post Share on other sites
starletezy Posted December 29, 2015 Author Share Posted December 29, 2015 your not reinforcing the chassi where the cage bolts down ??? the way its now the cage is just for show and has no safety feature really cage is mocked up in the pictures mate not bolted down yet and yes I have got all the reinforcement pates needed to reinforce the chassis its not for show... Quote Link to post Share on other sites
Amjad Posted December 29, 2015 Share Posted December 29, 2015 Nice write up! Quote Link to post Share on other sites
starletezy Posted December 29, 2015 Author Share Posted December 29, 2015 Nice write up! cheers mate Quote Link to post Share on other sites
Flynn Posted December 29, 2015 Share Posted December 29, 2015 You my friend are an absolute legend! Been um'ing and ar'ing about attempting this myself for about 6 months, thrown out questions and even tried putting bits into the car to determine exactly how much to chop! This will be invaluable, thanks for taking the time to write it up! Quote Link to post Share on other sites
Flynn Posted December 29, 2015 Share Posted December 29, 2015 Are you welding the cage into the car or just bolting up with the plates? Quote Link to post Share on other sites
starletezy Posted December 29, 2015 Author Share Posted December 29, 2015 You my friend are an absolute legend! Been um'ing and ar'ing about attempting this myself for about 6 months, thrown out questions and even tried putting bits into the car to determine exactly how much to chop! This will be invaluable, thanks for taking the time to write it up! Are you welding the cage into the car or just bolting up with the plates? no problems mate i was trying to find the same answer for a long time aswell! Its getting bolted in correctly along with reinforcement plates Quote Link to post Share on other sites
Flynn Posted December 29, 2015 Share Posted December 29, 2015 Keep us posted how it turns out! Quote Link to post Share on other sites
starletezy Posted December 29, 2015 Author Share Posted December 29, 2015 Keep us posted how it turns out! Will update with couple more pics once the cage is sprayed up and installed properly Quote Link to post Share on other sites
abbott Posted December 29, 2015 Share Posted December 29, 2015 Hi dude im glad you got it fitted shame it was a little hassel. But i would also sleeve the main hoop after its welded for extra strenth. But thats my advise. Fair play tho as most people would give up Quote Link to post Share on other sites
Flynn Posted December 29, 2015 Share Posted December 29, 2015 What do you mean by "sleeve" abbott? Sorry not a term I'm familiar with lol Quote Link to post Share on other sites
starletezy Posted December 30, 2015 Author Share Posted December 30, 2015 Hi dude im glad you got it fitted shame it was a little hassel. But i would also sleeve the main hoop after its welded for extra strenth. But thats my advise. Fair play tho as most people would give upCheers buddy just takes abit of patience all worth it seeing the end result sleeve were the plates sits at the bottom? Quote Link to post Share on other sites
turbo-fever Posted December 31, 2015 Share Posted December 31, 2015 Had this done to mine few months ago only down side is the cage sits lower then normal so more prone to banging your head lol Quote Link to post Share on other sites
turbo-fever Posted December 31, 2015 Share Posted December 31, 2015 Quote Link to post Share on other sites
Flynn Posted December 31, 2015 Share Posted December 31, 2015 Does it sit a bit on the piss along the length of the car, can't really see from the picture?Used to twat my head on the cage when it was in my SR so kind of got used to ducking in......still do it now out of habit lol Quote Link to post Share on other sites
starletezy Posted December 31, 2015 Author Share Posted December 31, 2015 (edited) Thats why you put foam around the roll cage lol Edited December 31, 2015 by starletezy Quote Link to post Share on other sites
turbo-fever Posted January 5, 2016 Share Posted January 5, 2016 Does look a bit pissed but it's tight to the roof all the way along its just the way the bars sit Quote Link to post Share on other sites
starletezy Posted January 6, 2016 Author Share Posted January 6, 2016 Does look a bit pissed but it's tight to the roof all the way along its just the way the bars sit Looks good mate Quote Link to post Share on other sites
Flynn Posted January 6, 2016 Share Posted January 6, 2016 Is that centre bar bang up against the roof, the big hoop one? Quote Link to post Share on other sites
starletezy Posted January 7, 2016 Author Share Posted January 7, 2016 Is that centre bar bang up against the roof, the big hoop one? No mate it clears the roof by 2cm so I would say its bang on Quote Link to post Share on other sites
turbo-fever Posted January 8, 2016 Share Posted January 8, 2016 Looks good mateCheers dude, yours looks pretty sweet aswell Quote Link to post Share on other sites
starletezy Posted January 13, 2016 Author Share Posted January 13, 2016 Cheers dude, yours looks pretty sweet aswellCheers mate in the process of getting sprayed in white now Quote Link to post Share on other sites
starletezy Posted May 15, 2016 Author Share Posted May 15, 2016 Update cage stubs welded painted and fitted Quote Link to post Share on other sites
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