Roll Cage Failures

Collapse
This is a sticky topic.
X
X
Collapse
First Prev Next Last
 
  • Filter
  • Time
  • Show
Clear All
new posts

    Roll Cage Failures

    The "Minimalist Cage Designs" thread inspired me to create this thread. There were a few good cage failure threads on pirate and I always though they were quite interesting/eye opening. I am hoping this can become a sticky thread since this is an important topic and I think there is quite a lot to be learned from failures and actual data points.

    Fortunately, I don't have anything to personally contribute, but I hope others can. This is not intended to be a "what do you think of my cage design?" or "If you build your cage out of poop pipe you're going to die!!!" thread.

    I am hoping people can post pictures of their cages after significant rollovers, whether or not they held up, and provide details of the rollover and design of the cage (diameter, wall thickness, material, etc.). Then we can all speculate on why the cage held up[ or not, and use these data points to improve future designs or establish what is "good enough".

    #2
    2 min 45 seconds into this video. We're racing and get cut off by one competitor who checks up and allows a much slower rig to get in front of us. If you watch the first two minutes you can see us trying to get around a car that's swerving around wildly, so while we need to get past him we're trying not to get taken out by him at the same time. At 2:42 I tell dad "we got him" and dad hammers down. I saw the speedometer at 70 mph when we hit the jump, but we land on the slower car. Our right rear comes down on his left rear and I think we were going about 20 mph faster than him. It pitched us straight to the A pillar and caused us to violently endo pirouette to a barrel roll. The sudden stop was hard enough to knock my dad (driver) out in a vehicle that with our HANS devices our helmets CANNOT touch anything. If you watch the video in segments you can see we roll over off the other cars tire, straight to our driver A pillar. When the A pillar digs in thats what pile drives the nose into the dirt. The main cage didn't bend at all, it just smooshed the nose in. We cut the front hoop off and raced in the main earning a 3rd place podium spot after starting dead last.

    https://www.facebook.com/KingofTheHa...zMzEzNzQ4MDY5/

    Photobucket is a piece of shit so no matter what I do I can't change the order of these pictures. The bottom pic is me driving it back to the pits from the crash spot showing pre repair.








    and here are a couple bare chassis pics from when it was new


    Last edited by JR4X; 07-01-2020, 11:38 AM.

    Comment


      #3
      Originally posted by JR4X View Post
      Reserving this post for content. I have pics and vid of a cage that held up to a 69 mph direct landing on the drivers side A-pillar. Still have the chassis. I have pics of another one that we can debate wether it was a failure or not. It saved my life but it was done after that. Wouldn’t have saved me a second time over. It’s Saturday and I’m at work. I’ll come back and edit this with mucho pics and vids.
      Awesome, great way to get the thread started

      Comment


        #4
        I used to sorta know someone with a jet engine in his truck.. saw him the wall at somewhere over 200mph.. he walked away.. kinda wonder how much they spent on the cage.. and if a cage that good would be overkill for 4x4s

        also, right before I totaled my 4x4.. I was gettin prices for cages.. speakin of a wide range of prices..

        Comment


          #5
          I went a bit overkill with the cage on my short course SxS just in case bad shit ever happens. Hopefully I won't be posting "after" pictures anytime soon.


          Click image for larger version
Name:	20200517_215437.jpg
Views:	793
Size:	417.7 KB
ID:	54497 Click image for larger version
Name:	20200624_164909.jpg
Views:	799
Size:	634.8 KB
ID:	54498
          Last edited by SLOWPOKE693; 06-28-2020, 04:46 PM.

          Comment


            #6
            Not mine but I saw this brand new SXS on the trail right after it happened.


            Click image for larger version
Name:	IMG_20190922_101100.jpg
Views:	907
Size:	346.0 KB
ID:	55246

            Click image for larger version
Name:	IMG_20190922_105420.jpg
Views:	905
Size:	572.9 KB
ID:	55247

            Click image for larger version
Name:	IMG_20190922_105846.jpg
Views:	907
Size:	735.7 KB
ID:	55249

            Click image for larger version
Name:	IMG_20190922_105858.jpg
Views:	900
Size:	423.9 KB
ID:	55248

            Comment


              #7
              Looks like some shit welds on that side by side. Particularly that door bar. No penetration at all.

              1992 YJ Unlimited +
              Tons, 40s and stuff

              Comment


                #8
                Originally posted by 92 Green YJ View Post
                Looks like some shit welds on that side by side. Particularly that door bar. No penetration at all.
                Every single one of those stock cages, no matter what the brand, is a death trap. Welds suck and the tubing is like .045 wall. I swear your probably better off pulling the factory cage and ducking in a rollover. At least then you don't have to worry about the "cage" coming down on you.

                Honestly, I can't believe there hasn't been tons of lawsuits over that yet.

                Comment


                  #9
                  Here is one I saw last year that got T-boned. Not good.....

                  Click image for larger version  Name:	20180521_165236.jpg Views:	0 Size:	644.2 KB ID:	55662 Click image for larger version  Name:	20180521_165300.jpg Views:	0 Size:	586.7 KB ID:	55665 Click image for larger version  Name:	20180521_165428.jpg Views:	0 Size:	491.4 KB ID:	55664 Click image for larger version  Name:	20180521_165247.jpg Views:	0 Size:	479.6 KB ID:	55663
                  Last edited by SLOWPOKE693; 06-29-2020, 07:56 PM.

                  Comment


                    #10
                    The interesting thing to point out about the Maverick cage is that besides the crappy weld failure, all of the apparent tube failures are where reinforcements were added and created stress risers. The swept back A-pillar is obviously done primarily for styling and left it very week. Can-Am is obviously aware that is is a poor design since they added the big gusset at the primary bend to reinforce the A-pillar, but this reinforcement may have been more of a detriment seeing as it caused the tube to kink/buckle rather than just bend to give a little. Had it had a secondary A-pillar like this buggy to create some triangulation and support that sweeping roofline, things probably would have went better Click image for larger version
Name:	imageuploadedbyag-free1413826428-021166-jpg.1496314.jpg
Views:	717
Size:	75.4 KB
ID:	55699

                    All that said, it does look like the cage did adequately protect the driver, so it did serve its purpose. It just could have been designed/built better so that it could have been used more than once.

                    Comment


                      #11
                      Originally posted by JR4X View Post
                      Reserving this post for content. I have pics and vid of a cage that held up to a 69 mph direct landing on the drivers side A-pillar. Still have the chassis. I have pics of another one that we can debate wether it was a failure or not. It saved my life but it was done after that. Wouldn’t have saved me a second time over. It’s Saturday and I’m at work. I’ll come back and edit this with mucho pics and vids.
                      And then......

                      Comment


                        #12
                        Click image for larger version
Name:	Screenshot_20200630-180142.png
Views:	676
Size:	1.10 MB
ID:	57012
                        I have the same rig as above, I thought honda did OK using 2" and a little be design than some of the others. I guess I didn't think they would be dumb enough to use stupidly thin tubing.


                        You guys need your eyes checked. The weld did not fail, the tubing ripped open. Again, a result of way to thin of material.

                        Comment


                          #13
                          Alright guys, let's try to get a little tech in here instead of just making this a dump for pictures you found on the internet. Please try to post some basic information with the pictures such as tubing size and material grade as well as what were the conditions of the roll over were, i.e. speed, number of rolls, etc.

                          Also, I would prefer to discuss actual rigs instead of factory cages on golf carts Perhaps if it is a custom cage it would be worth posting up. The intention of this thread is for people to learn and see first hand the performance of various roll cage designs so that they may be able to determine what is "good enough" for their particular build or to avoid making critical design mistakes.

                          Comment


                            #14
                            Originally posted by SLOWPOKE693 View Post

                            And then......

                            I'm trying The video I need to attach is the Ultra4 Stampede - Rancho Cordova Cali 2017. If P4x4 worked right I could find the video, I can't find it anywhere now. Gonna be hard to adequately describe the context without the video. Need more time to dig.

                            Comment


                              #15
                              not sure id call mine a failure, it did what it was supposed to do and kept the occupants alive. a few small changes and chances are i would have revived the truck. door bars and sub belts. all tube was 1-3/4x.120

                              my build thread - http://www.pirate4x4.com/forum/toyot...ck-thread.html

                              thing to remeber is to keep the seats attached to the cage. this way in the even the body separates from the chassis you are in the cage. think of it the way an f1 car explodes.

                              mine did its job, kept me and my wife (gf at the time) alive. we both ended up with staples in the dome, could have been avoided if the sub belts where installed. see the thread for the discussion regarding this. no one saw me roll since my buddy was on his bike. given the way i ended up and damage on the vehicle im fairly certain i was airborn at one point. cage stayed centered in the cab,

                              the front end and the cab stayed put fairly well. door bars would have kept it solid, didnt have em though you could see where the dash bar bent as the the front corner tried pushing itself through the cab. the back of the truck too a big hit and bent bad just past the shock mounts. understandable since there was no lateral support past that point. back half and links would have been the ideal solution. decided to get married instead of rebuilding.

                              in the far away shot you can see where i made contact with the bank and where the truck ended up.







                              Attached Files
                              Last edited by mobil1syn; 07-01-2020, 12:59 PM.

                              Comment

                              Working...
                              X