Setting the roll bar into position - 4 hours

 The plans have the rear of the roll bar set at a specific position. I used tape to mark out the 7/32” offset to the inside. Using a piece of aluminum angle I then set the forward/aft position of the roll bar. After checking correct positioning a number of times…I was ready to drill.

 

Using the 90deg pneumatic drill…I back drilled the #40 pilot hole on the pilots side to mark the roll bar. Done and Done.

Now…The roll bar is slightly wider than the required dimension. I need to squeeze it in about 1/4” to get the fit right. Well I leaned on it. Nothing. More and more leaning. Get my belly/weight right into it. Nothing. Now this is concerning….I’m a solid 220 right now. Not even a budge. I decided that I will have to use a ratchet strap on it. 

It’s very easy to start squeezing it together. I started at 1” and then basically went up at 1/4” increments checking at various milestones. Think I squeezed up to 2 1/2” and absolutely no change. I finally threw in the towel. I think I am going to have to get more aggressive with it.