Custom Roll Cages
The single component that decides whether you walk away. We design, jig and weld competition cages to the rulebook — no shortcuts, no decorative tube.
A roll cage is the spine of a rally car. Everything else — the suspension pickups, the seat mounts, the way the shell resists twisting over a fast crest — hangs off how well the cage is designed and welded. We build cages that are scrutineer-legal first and stiff second, because a structure that passes paper but flexes in a barrel roll is worth nothing.
Every cage we build starts as a CAD layout mapped against the current Motorsport Australia and FIA Appendix J requirements for your class. We then jig the car, bend each tube on a mandrel former, notch the joints for full contact, and TIG-weld the structure in a controlled sequence to manage heat and distortion.
Designed around the rulebook and the driver
Cage regulations are not suggestions. Tube diameter and wall thickness, the number of door bars, backstays, harness mounting bars and the position of the main hoop are all dictated by your competition category. We hold current copies of the relevant schedules and design to them — then submit drawings where homologation or logbook sign-off is required.
Within those rules there is room to build a cage that actually fits the human inside it. We set the main hoop and door bars around your seating position and helmet clearance, route the dash bar so you can still reach the controls, and make sure the co-driver has the same protection as the driver. A cage you have to fight past to get in is a cage you will resent on event morning.
Fabrication that earns the logbook stamp
We bend cold on a mandrel to avoid kinking and wall-thinning, fishmouth every joint so tubes seat fully before welding, and add gussets and tube plates at the highly loaded nodes. Welding is done in sequence to keep the shell straight, with full-penetration TIG runs you can actually inspect.
Where the rules allow, we tie the cage into the strut towers and floor with load-spreading plates, turning the cage and shell into one stiff structure. The payoff is not just safety — a properly triangulated cage sharpens turn-in and makes the car feel like it pivots from one point instead of folding around the middle.
What's included
- CAD design to your competition category
- Mandrel-bent CDS, T45 or chromoly tube
- Notched, gusseted, fully-welded joints
- Strut-tower and floor tie-in plates (rules permitting)
- Harness, seat and FE-bottle mounting bars
- Removable door bars / NASCAR bars on request
- Logbook documentation and scrutineering support
