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-   -   Cool Tech Roll Bar - Sneak Peek (https://themustangsource.com/forums/f813/cool-tech-roll-bar-sneak-peek-502918/)

nota4re 12/10/11 09:12 AM

Cool Tech Roll Bar - Sneak Peek
 
5 Attachment(s)
Cool Tech LLC is very excited to pre-view the availability of a bolt-it roll bar kit designed specifically for the 2012-2013 Boss 302 Mustang Laguna Seca models. Please note that this bar can also be used in 2011-2013 Mustang GT (Coupe) and Boss 302 models in conjunction with a readily available (approximate $100) rear seat delete kit. Cool Tech invested many hours of R&D in developing a kit that was “worthy” of these extremely capable, track-ready cars. We sought to create a kit that an owner could self install and that enhanced both the safety AND the performance capability of the car. We also wanted to minimize any cutting, drilling, or modifications to the car enabling an owner to have the option to remove the bar and return to a fully OEM configuration should they ever decide to do this. Of course, the bar had to also respect the pragmatic and ergonomic capabilities of the OEM car – respecting seat travel, recline, and safety belt access and function. With all of these as design constraints, ultimately creating a solution that could meet our expectation was no easy undertaking. However, we are very proud to say that we have been successful and we will now offer a very good solution for your consideration.
Construction:
Our roll bar kit is constructed using the same tubing specifications as required by the SCCA for road racing classes. Namely, 1.75 inch x 0.120" wall DOM (Drawn Over Mandrel) tubing throughout. (Note: SCCA requires full roll cages in all road racing classes.)
Unlike many other roll bars which employ a MIG welding process, the Cool Tech bar is entirely TIG-welded.
The Advantages of TIG Welding:
· TIG is Clean: TIG welding doesn't create as much spatter and sparks as MIG thus creating a better, cleaner finished product..
· Autogenous TIG Welds: TIG welding can create autogenous welds - those that do not involve any filler material. The weld is created when the part melts together. By controlling the filler material and the amount of filler, the welder has better control to create superior welds. Note: TIG is used almost exclusively in the aerospace community because of these attributes.
· TIG is Precise: TIG welding offers more precision when it comes to thin materials. It produces welds without contamination.
Let’s get to some *preliminary* pics of the work in progress:
Attachment 97414
Here is a picture of the roll bar base just inside the driver’s door. In this picture, you can see the bottom of the main hoop has been welded to a piece of 90-degree metal which in turn is bolted to a gusset (3 Grade-8 gold-colored bolts shown). In this sneak-peak, the roll bar has yet to be finish welded to the base plate. (Note that the square bar shown is a temporary piece and is not part of the finished product.) The intent of this picture is to show the large gusseted structure that the roll bar is bolted to. This large fabricated gusset replaces a comparatively smaller, thinner, stamped OEM piece that is removed (un-bolted) as part of the installation. These heavily reinforced gussets (one per side) are part of the Cool Tech kit. Notice that the gusset bolts into place – literally re-using the bolts and OEM attachment points of the original plate. All of the Cool Tech components shown here will come fully powder-coated and will bolt in with no cutting or drilling required. These engineered bases for the main hoop provide an incredibly strong and reinforced mount for the main hoop. The gusseted piece is essentially identical on the other side of the car. Once again, there is no cutting, drilling, or welding – yet an incredibly strong structural tie-in.
Attachment 97415
This is a picture of the main hoop and harness bar in the car during fabrication. (Note that the harness bar has a seam in the middle as this is simply the template-bar and production pieces will have no seam.) Notice that the main bar uses two bends in order to maintain a consistent spacing with the roofline. This was one of the design requirements for us. Also notice that the seat-belt extender has a good fit out and around the bar and that the bar may aid in the access of the belt and it does not hinder the usability of the OEM belts – another design requirement. Finally, in this picture, notice the rearward curvature of the harness bar. As a tall (6’ 2”) driver myself, the roll bar accommodates the seats in their most rearward position AND with a relatively substantial recline (if desired). Compare these design features with other bars that may be available.
Attachment 97416
This picture may provide a better perspective of the roofline conformance as well as the placement of the bar in relation to OEM seat belt access and usage.
Attachment 97417
Cool Tech has opted for a roll bar design that, in addition to safety and strength, the installation all directly aims at providing a stiffer chassis for better car performance. This is a picture of the passenger side rear shock tower which has been significantly reinforced with the gusseted bracket included with our kit. Note that a cross bar has been welded (only tacked in this work-in-progress pic) to the gusset. The Cool Tech Roll Bar will incorporate a rear shock tower brace that reinforces the structural integrity and stiffness of the rear suspension – but simultaneously provides a rear mounting platform for the diagonal braces from the main bar. The vertical plate of this gusset is 3/16” steel and bolts into a backing plate on the opposite side. This is an incredibly strong structure – reinforcing the roll bar integrity and also stiffening the suspension components by tying everything together into rigid structure. (Note that Cool Tech will offer the shock tower brace seperately for those that want to have the stiffening benefits but who do not want to install a roll bar.)
Attachment 97418
Finally, here is the diagonal coming down from the main hoop and intersecting the strut tower brace. Notice the precise fish-mouthed fitment of the tubing – all a pre-requisite for the TIG-only welding through-out the entire kit. The angle of this rear main hoop support brace has been chosen to eliminate any cutting on the rear deck plate (see blue tape). Additionally, such placement will require a relatively simple notching of the interior trim piece – another consideration during the design. The Grade-8 bolts in the 3/16” plate represent the only holes that will need to be drilled in the car for the installation of our kit. To make this even easier, these bolts have been placed over un-used holes in the OEM shock tower gusset. This makes locating and drilling of the holes very easy.
We still have some other features to show... give us a couple of days. The first (sold) batch of 5 roll bars will be completed next week and off to get powder-coating. All of these initial buyers opted for the race red for the interior of LS models but we can also do other colors. We should have final pricing as well as some additional pictures by mid to end of next week.

BlackMamba03 12/10/11 09:16 AM

That looks so legit. You should have powder coated it though.

BlackMamba03 12/10/11 09:20 AM

Ignore my first post. I read where they will come powder coated.

boss man 12/10/11 09:27 AM

That looks like a very well built roll bar.
1+

ulev1st 12/10/11 09:35 AM

Soooo glad to get in on the first run batch! Thanks Kendall! A QUALITY product as always!
Don

5 DOT 0 12/10/11 10:16 AM

Wow, that looks like a quality piece of work if there ever was one. No roll bar for me as I have kids that like to ride back there but I'm interested in the rear shock tower brace.

When you finish with this project you should consider making a 1" front splitter lowering kit made out of the same OEM plastic as the front valance and splitter. ;)

01roushstg1 12/10/11 10:45 AM

I like the kit. Good work.

2006mach1 12/10/11 11:08 AM

Looks great! Waiting on price now.....

Dean#4AI 12/10/11 11:12 AM

Looks like a quality piece! Now the bad news, what's it going to cost?

Jza1736 12/10/11 11:19 AM

Hey kendal,

Very nice I'm very interested! Will I need another bar for the harnesses or do they clip to it? I planned on a harness bar next year but from what I'm reading a full roll bat is the way to go.

2006mach1 12/10/11 11:57 AM

Kendall, will there be a diaganol brace/bar in the main hoop? Or is it not really required?

2012YellowBoss 12/10/11 12:05 PM

Kendall, what are you using to attach the belts. I was sent eyebolts but they were not the correct threads, the factory thread is 10x1.5. I want to avoid drilling new holes for the harnesses connections if possible and have all the belts attached at the same points. Let me know how you are doing this, thanks.

2 Go Snake 12/10/11 12:30 PM

I am really impressed with the rollbar setup. The rear seat delete kit for the 2011 -2013 Mustang GT really excites me. I would hope a rear seat delete and rollbar will be available for the 2005 - 2009 Mustang GT. I would be more apt to put a rollbar in a used GT from 2005 to 2009.

jim woodruff 12/10/11 01:05 PM

Cool tech- That is a great set up and design it looks like installation will be quick. I fyou are lookin for a new products to build and I would like to suggest two, The shocks in the reat are a pia to adjust. I remember I had old set of Koni,s that had a large knob that fit in the slot in the top you just put it in a counted the clicks. The second would be a jacking plate kit like the old Porcshe,s with all the lines under the car this would prevent crushing problems. Just a couple of items I would like to see.

5 DOT 0 12/10/11 02:13 PM


Originally Posted by jim woodruff (Post 6197385)
If you are lookin for a new products to build and I would like to suggest two, The shocks in the reat are a pia to adjust. I remember I had old set of Koni,s that had a large knob that fit in the slot in the top you just put it in a counted the clicks. The second would be a jacking plate kit like the old Porcshe,s with all the lines under the car this would prevent crushing problems. Just a couple of items I would like to see.

Both of these are terrific ideas. :nice:

06GT 12/10/11 02:22 PM

Looks great. I'd be concerned about shearing that rear crossbar from the shockmounts in the event of an actual rollover, however. Typically you see the downbars going directly to the boxes you have around the rear shocks. I understand that you likely designed this way to conform to the stock trunk pass-through opening.

Some very nice craftsmanship going into this kit, though!

06GT 12/10/11 02:24 PM


Originally Posted by 5 DOT 0 (Post 6197420)
Both of these are terrific ideas. :nice:

Agreed.

Dig-It Racing 12/10/11 02:53 PM

Wow! I'm looking forward to seeing the finished product.

Zoldier 12/10/11 03:28 PM

Kendall is going to be the main reason for my divorce. Not facebook like all those other normal couples. :D

ulev1st 12/10/11 04:25 PM

^:agree:

CaptDistraction 12/10/11 05:35 PM


Originally Posted by 06GT (Post 6197425)
Looks great. I'd be concerned about shearing that rear crossbar from the shockmounts in the event of an actual rollover, however. Typically you see the downbars going directly to the boxes you have around the rear shocks. I understand that you likely designed this way to conform to the stock trunk pass-through opening.

Some very nice craftsmanship going into this kit, though!

That's something that caught my eye as well. Wasn't sure If this bar could be expanded into something for race use in the future with that particular design trait.


Very pretty and well thought out work!

nota4re 12/10/11 06:49 PM

Thanks for all the comments and observations, everyone. It is encouraging to be at this point in the project and the feedback is welcomed and appreciated. Regarding the strength of the rear support for the diagonal braces, I will improve upon the pictures hopefully during this coming week as the project makes progress. What can't be seen is that the "box" also has a base which is bolted down as well with the top of the shock mount. This fabricator is VERY experienced in building professional cages... let's wait for the next update.

As for growing this system into a fully certified cage - I suppose with enough work anything could be done (and I wouldn't discourage it) but at the same time this is not our target audience. We are targetting GT and Boss owners who enjoy tracking the car and who have advanced enough to want full harnesses and who want the extra protection of a roll bar. It provides what we believe is a very reasonable extra margin of safety but, like virtually any system, it is not immune to failure as we cannot predict all of the scenarios - that we hope no one experiences. If you purchased your Boss with the potential to one day turn it into a professional race car where you are doing more wheel to wheel racing, then we would advocate that you abandon some of the other more street-oriented constraints and go for a full weld in 4 or 6-pt bar/cage.

Again, thank you for the feedback.... we'll have some more updates soon!

CaptDistraction 12/10/11 07:02 PM

Good stuff, keep it up!

2 Go Snake 12/10/11 08:03 PM

I like all the ideas presented. If there is a choice of getting a MIG welded roll bar kit for less money but of the same dimensions and near quality of the Tig welded roll bar, I would be interested in using the kit in a 2007 Mustang GT for drag racing. This would not be for a class requiring a roll bar, just for extra safety on the street and strip. The more I look at the roll bar featured in this thread, the more I like it.

ulev1st 12/11/11 09:25 PM

Randall.....any pictures from the inside of the rear down bars to the shock crossbar?

rmaginnis 12/11/11 10:45 PM

1 Attachment(s)
Wow, this looks is sick!:metal:
Questions I have is how do you put the assembly into the car when pre-welded? The rear tower cross bar and diagnals from main hoop look too close to inner body panels to just 'slide' in place. I assume that rear shocks need to be lowered out of the way prior to?
Nice job!

2 Go Snake 12/11/11 11:24 PM

That was my question also, how do they get the bar in with so very close tolerances to the interior panels ? The reason I am so impressed with the bar is bacause of how close the bar is to the inside of the body. A really hansome rollbar. Best I have seen.

Sabre 12/12/11 08:23 AM

Please tell me you have intentions of doing the same roll bar for the 05 - 09 model years...SOON....for those of us who track our 05 - 09 cars....our options for good roll bars are sorely limited!!

nota4re 12/12/11 08:29 AM


That was my question also, how do they get the bar in with so very close tolerances to the interior panels ?
Yeah, the good news is that the bar will look great installed. As for the installation process, the plastic side panels ain't gonna be any fun. It is easy enough to put the main hoop in and out but when it comes time to fit it with the side panels in place - all will need to be done together. One option we are considering is to also offer the side panels pre-trimmed. This way, the truly anal owners (like me!) would; 1) have the option to keep their OEM un-trimmed panels tucked away and; 2) wouldn't have to worry about doing the needed panel trimming.

All of these pics ar of my car as we get the roll bar fitted and the jigs made to repeat the bar for production. The first 2 production bars WE will be installing. (Oh joy!) The first one will be used to create the installation instructions and tips. We HAVE already proven out the fitment with the trimmed panels.... I just didn't get the opportunity to get any pics to share yet. More soon (this week).

Jza1736 12/12/11 08:33 AM


Originally Posted by nota4re

Yeah, the good news is that the bar will look great installed. As for the installation process, the plastic side panels ain't gonna be any fun. It is easy enough to put the main hoop in and out but when it comes time to fit it with the side panels in place - all will need to be done together. One option we are considering is to also offer the side panels pre-trimmed. This way, the truly anal owners (like me!) would; 1) have the option to keep their OEM un-trimmed panels tucked away and; 2) wouldn't have to worry about doing the needed panel trimming.

All of these pics ar of my car as we get the roll bar fitted and the jigs made to repeat the bar for production. The first 2 production bars WE will be installing. (Oh joy!) The first one will be used to create the installation instructions and tips. We HAVE already proven out the fitment with the trimmed panels.... I just didn't get the opportunity to get any pics to share yet. More soon (this week).

Can't wait! You guys have done some great work!!

nota4re 12/12/11 08:34 AM


Please tell me you have intentions of doing the same roll bar for the 05 - 09 model years...SOON....for those of us who track our 05 - 09 cars....our options for good roll bars are sorely limited!!
Thanks for asking but realistically, not anytime soon. The fabricator that we are using does a lot of interior-gutted and tubular chassis "REAL" race cars and seldom takes on a job for a car with an interior to work around. I'm not sure that he want to see another "interior'd car" for awhile. Keep in mind that my car has been in his shop for 5 WEEKS now.... going on 6! This is a much "harder" and more challenging problem to solve than I had originally thought.

Sabre 12/12/11 10:54 AM


Originally Posted by nota4re (Post 6198249)
Thanks for asking but realistically, not anytime soon. The fabricator that we are using does a lot of interior-gutted and tubular chassis "REAL" race cars and seldom takes on a job for a car with an interior to work around. I'm not sure that he want to see another "interior'd car" for awhile. Keep in mind that my car has been in his shop for 5 WEEKS now.... going on 6! This is a much "harder" and more challenging problem to solve than I had originally thought.


Thanks...I understand.

You don't know until you ask...so I asked.

Keep it in mind though...when you get this project wrapped up and in production. I still believe there would be a big market out there, for another cage option for 05 - 09 S197...especially one that is going to look as nice as yours is going to.

RJorge1950 12/12/11 11:06 PM

Roll Bar
 

Originally Posted by nota4re (Post 6198245)
Yeah, the good news is that the bar will look great installed. As for the installation process, the plastic side panels ain't gonna be any fun. It is easy enough to put the main hoop in and out but when it comes time to fit it with the side panels in place - all will need to be done together. One option we are considering is to also offer the side panels pre-trimmed. This way, the truly anal owners (like me!) would; 1) have the option to keep their OEM un-trimmed panels tucked away and; 2) wouldn't have to worry about doing the needed panel trimming.
All of these pics ar of my car as we get the roll bar fitted and the jigs made to repeat the bar for production. The first 2 production bars WE will be installing. (Oh joy!) The first one will be used to create the installation instructions and tips. We HAVE already proven out the fitment with the trimmed panels.... I just didn't get the opportunity to get any pics to share yet. More soon (this week).

Hi nota4re !

It's me Rob, just had to join TMS so I can be able to follow your thread and keep up with the progress that you are making. Hope I don't have to get divorced like the other guy LOL.
The panel idea is a great one as the LS is a limited production car that most owners would like the ability to bring the car back to stock. This roll bar is not intended for wheel to wheel racing but it gives us added safety when using the car on track days. It provides a solid platform to mount a 4 or 5 point harness, and it looks killer ! :nice:
As for the diagonal brace, it would help structually but it would defenitely interfere with the seat travel. I would be fine without it.
As for the rear bar being hard to install you may look at doing a bolt on flange that attaches from the horizontal tube to the side bracket on each side of the rear struts. This way you can first bolt on the brackets then bolt the bar to the brackets. Just my 2 cents
Sorry to hear that you have your car tied up for six weeks but it's for a good cause.

Best regards,

Rob

2 Go Snake 12/13/11 07:00 PM

It may be awhile before a rollbar becomes available for the 2005-2009 Mustang GT, but at least we have hope it may happen. I dont know the difference between interior dimensions of a 2012 as opposed to a 2005-2009 GT. Maybe as more Kel-Tech rollbars become available, someone will get a tape measure and see if the bar would fit a 2005-2009 GT. A rollbar would add some safety even on the street. Too bad, Ford could not offer a rollbar as an option.

boss man 12/14/11 05:50 AM


Originally Posted by 2 Go Snake (Post 6199204)
It may be awhile before a rollbar becomes available for the 2005-2009 Mustang GT, but at least we have hope it may happen. I dont know the difference between interior dimensions of a 2012 as opposed to a 2005-2009 GT. Maybe as more Kel-Tech rollbars become available, someone will get a tape measure and see if the bar would fit a 2005-2009 GT. A rollbar would add some safety even on the street. Too bad, Ford could not offer a rollbar as an option.

You are right in stating A rollbar would add some safety even on the street. If I'm correct there are 4 totaled 2012 Bosses and 3 of them rolled. Makes you wonder :hmm:

Tob* 12/14/11 10:40 AM

Kendall, what I appreciate most here is your ability to be clear and concise. You articulate your thoughts very well and obviously have a good grasp on our native tongue - thanks for no lol's. Perusing your site, I can see you have some very well engineered products for sale. Good show.

Because I happen to spend some time behind a welding mask as well as having installed a couple of 'bars' before, I saw mention of a few things here and would like clarification, if you can.

Regarding your initial post...


Originally Posted by Kendall
TIG is Clean: TIG welding doesn't create as much spatter and sparks as MIG thus creating a better, cleaner finished product

I can't argue that overall, the TIG process may be inherently 'cleaner' than if one were to MIG, but spatter or sparks don't necessarily produce an inferior fusion point. I would argue that the TIG process offers the potential to produce more precise welds with a more tightly controlled heat affected zone.


Originally Posted by Kendall
Autogenous TIG Welds: TIG welding can create autogenous welds - those that do not involve any filler material. The weld is created when the part melts together. By controlling the filler material and the amount of filler, the welder has better control to create superior welds.

Without introducing any type of filler rod, an autogenous weld will reduce/relocate the base material on the tubes to be joined. For structural purposes, I'm not sure that is going to produce the strongest joint were an accident to occur that deformed the vehicle or 'roll' bar.


Originally Posted by Kendall
TIG is Precise: TIG welding offers more precision when it comes to thin materials. It produces welds without contamination.

Argon, whether used in the TIG process or in the MIG process has the same effect regarding shielding gases and their ability to ward off contaminants.

I like your logic regarding the harness bar. I suppose an argument could be made that the strongest bar in this location would be in a single plane and thus have no bends, but comfort level would be seriously degraded for taller drivers that need more room. I prefer the way you are doing it and I'm sure many others will as well.

Its good to see some bar manufacturers are using the rear bulkhead to their (structural) advantage, as opposed to mounting the downward portion of the main hoop over the flat portion of sheetmetal aft of the front seats ('stiffening' plate or not). I think it was Maximum Motorsports that first used this to their advantage on a large scale with their S197 bar offerings.

That said, I notice that the factory incorporates a triangulated section in their stamping that runs from the rocker (at the bottom of the B pillar) to the bulkhead

http://i772.photobucket.com/albums/y...f?t=1323879715

I notice that Maximum took the time to add this section as well via a triangulated and welded section...

http://i772.photobucket.com/albums/y...f?t=1323879678

I notice that yours doesn't utilize it...

https://themustangsource.com/attachm...sset_right.jpg

Have you compiled any data or finite element analysis that shows it to be unnecessary? Just curious.

Regarding fitment for '07-'09 models (or back to '05, essentially) almost every manufacturer lists their bars as being '05+. Some have been to lazy to include '10 and later years but other manufacturers specifically state that their bars fit '05-'12 S197's. The roof has yet to change and I do not believe there have been any changes to either the rear shock tower stamping or its location relative to each side. That is not to say that minor plastic trim pieces may be affected, but I'd proffer that field verification is the only sure way to be certain (obviously).

And finally, unless I'm missing something, I don't see how the entire main hoop/down bar/shocktower bar and bracket could possibly be 100% welded. Shipping would be a nightmare, let alone installation. You've gotta have a break somewhere...

nota4re 12/14/11 02:58 PM

Hey Tob,

Thanks a lot for your very thorough comments and feedback. I don't think I did such a good job of the TIG:MIG comparison. I was really only trying to make the point that for me function AND aesthetics are both important in anything that goes into this car. For me, TIG welds are typically (but not always) better looking than MIG weld and that for this improved "look" there is not a compromise in performance. MIG'd bars, IMO, are NOT inferior in strength to TIG. Perhaps it comes down to personal preference.


I like your logic regarding the harness bar. I suppose an argument could be made that the strongest bar in this location would be in a single plane and thus have no bends, but comfort level would be seriously degraded for taller drivers that need more room. I prefer the way you are doing it and I'm sure many others will as well.
I don't think we are compromising strength in the primary function of the harness bar in the design we have done. The harness bar's primary purpose is in anchoring the harnesses and we can predict/model the forces acting on the bar which are almost exclusively directly forward. As such, there could be an argument that this "bowed" bar may even be stronger than a straight bar - but the topic is likely moot because both designs are over-engineered for this purpose. As far as this bar contributing to the overall strength of the primary hoop then, yes, there may be some differences. Our bar design will allow full travel of both the driver and passenger seats AND with more-than-normal recline angle. Not sure how many other solutions will offer this. (As I said, we are late to a market where solutions are already available so we have to find ways to improve and differentiate.)

I'm pretty certain that our fabricator has never seen the MM bulkhead piece and it is definitely a good piece. That said, I think the trangulated piece will find it's way into our very first examples. ;) Hat's off to MM for a fine design in this area but the bulkhead is a naturally strong and attractive location for securing the main hoop.


And finally, unless I'm missing something, I don't see how the entire main hoop/down bar/shocktower bar and bracket could possibly be 100% welded. Shipping would be a nightmare, let alone installation.
100% welded AND bolt-in would be the Holy Grail.... but we haven't achieved it either! So, yes, we have included joints in order to make the bars user installable and I will show some pictures of these shortly!

<Sorry readers for another long post/response.... but one more thing to say!>

Our target client is the owner who likes to participate in track events on weekends and during the week, the car is either a daily driver and maybe even a car that the owner likes to take to local car shows and gatherings. The target client wants a bar that will 1) offer increased roll-over protection; 2) allow for the securing and wearing of shoulder harnesses; 3) that looks great installed in the car. A prospective client who is racing more seriously or intends to engage competitively in SCCA events or other wheel to wheel racing venues would be well-served to look at more robust (full) cage kits and most likely, weld-in cages that could meet the SCCA requirements. We don't advertise or try to be the end-all, be-all of roll bars!!

Again, thank you for the feedback.... I gotta make a call now to insure some more gussets are added!

Tob* 12/14/11 05:47 PM

Very eloquent! You definitely have my full attention and you can add me to the list of those interested in this offering that owns an '07-'09 S197 chassis car.

Keep up the good work!

GT_350 1/5/12 07:42 PM

Since it's been three weeks I thought it would be OK to ask if there are any updates.

I know the first five have been spoken for but when you are ready I'd like to know if you are accepting orders...............

I have a Sparco seat and Schroth harness that are lonely and would like to meet an eligible Roll Bar!

nota4re 1/5/12 08:28 PM

Thanks for asking! We're almost there! Sorry it has been so long. I expect 2-3 weeks and this forum will be first to know. I REALLY appreciate the interest!

Jza1736 1/5/12 08:58 PM


Originally Posted by nota4re
Thanks for asking! We're almost there! Sorry it has been so long. I expect 2-3 weeks and this forum will be first to know. I REALLY appreciate the interest!

Are you going to do a limited supply or make them as ordered?

My car is in storage and I am planning on getting a roll bar set up come spring time.

nota4re 1/5/12 10:29 PM


Are you going to do a limited supply or make them as ordered?

My car is in storage and I am planning on getting a roll bar set up come spring time.
We have the first 5 more or less spoken for which is good for us because 3 of the cars are local and we will do the installs here and make sure we are happy with everything in terms of fitment/installability. After that we would like to have them in stock - minimally built but not powdercoated until we know what the customer's fininshing (if any) preferences are. If we know that black and race red (for example) sell well, then we would strive to keep those in stock. Mary Kay colors would always be special order :)

Jza1736 1/6/12 12:15 AM

So I will have to wait for pink, ****! I will be looking for white around spring time. Any idea of cost yet?

boss man 1/6/12 11:38 AM


Originally Posted by Jza1736 (Post 6215456)
So I will have to wait for pink, ****! I will be looking for white around spring time. Any idea of cost yet?


PINK WTF

Jza1736 1/6/12 11:41 AM


Originally Posted by boss man

PINK WTF

I was kidding dude :)

nota4re 1/6/12 11:55 AM


I was kidding dude :)
Oh crap, they're painting it now! :)

2 Go Snake 1/6/12 12:08 PM

All updates on the rollbar are greatly appreciated. Always enjoy hearing about your progress. :grin::grin::grin:

RJorge1950 1/9/12 07:14 PM

Hi Kendall !
Always great to hear about the progress you are making with the bar. Do you have anything on the custom Boss five point harness for the bar ? I would prefer to order the bar and harness together. If you have any prices please PM me as I have to decide between the bar, kooks full system or the divorce.
Best regards,
Rob

ulev1st 1/9/12 08:23 PM

Kendall...you previously mentioned a possible option of "pre cut/fit panels"..If that is an option when it comes time to build/powdercoat(LS Red) my bar..please shoot me a price for this option..Thanks Don

MrGT5oh 1/11/12 09:10 AM


Originally Posted by nota4re (Post 6215407)
Mary Kay colors would always be special order :)

That's a shame, I work at Mary Kay and thought pink would look great in my LS. I guess I'll have to order a red one.

I am one of those anal owners that would like to be able to keep the car as original as possible, that being said, how many holes will need to be drilled to accommodate the roll bar? Also, I would be interested in having the pre-cut interior pieces available with the kit.

SneakyE 1/11/12 11:06 AM


Originally Posted by MrGT5oh (Post 6220312)
That's a shame, I work at Mary Kay and thought pink would look great in my LS. I guess I'll have to order a red one.

I am one of those anal owners that would like to be able to keep the car as original as possible, that being said, how many holes will need to be drilled to accommodate the roll bar? Also, I would be interested in having the pre-cut interior pieces available with the kit.

Robert,

That makes two of us at Mary Kay. Are you at TMKB? You need to drive it to work sometime. Mine's a daily driver so it's in the parking garage almost every day.

Dig-It Racing 1/11/12 11:22 AM


Originally Posted by MrGT5oh (Post 6220312)
... I am one of those anal owners that would like to be able to keep the car as original as possible, that being said, how many holes will need to be drilled to accommodate the roll bar? Also, I would be interested in having the pre-cut interior pieces available with the kit.

I'm also interested in keeping the original interior pieces intact and ordering pre-cut replacements.

5 DOT 0 1/11/12 11:37 AM


Originally Posted by MrGT5oh (Post 6220312)
That's a shame, I work at Mary Kay and thought pink would look great in my LS. I guess I'll have to order a red one.

Maybe you should try this:

http://i918.photobucket.com/albums/a...g/pinkboss.jpg

nota4re 1/11/12 11:38 AM


I am one of those anal owners that would like to be able to keep the car as original as possible, that being said, how many holes will need to be drilled to accommodate the roll bar? Also, I would be interested in having the pre-cut interior pieces available with the kit.
Anal owners unite!!! (I'd like to think I am one too!!)

Let me address the questions.

Regarding the panels. There are two reasons that people may want the panels from us. One, getting new panels will allow the owner to retain his/her existing panels in their virgin OEM form. Second, getting panels from us that are "pre-modified" will aid in the installation process - less for the customer to do. Obviously, many prospective customers would say yes to both reasons.

I purchased a pair of these panels with the intention of confirming 1) that I got the right panels and; 2) what the packaging was. The good news is that I did indeed get the right panels and the bad news is that the boxes are very large. Our challenge is in packaging/shipping and how do we achieve this in the most economical way. We are still looking at that. Additionally, we are looking at the "degree of difficulty" of the panel mods that would be needed and how easily the average DIY'r could do these mods themselves. Just to be completely transparent - we seek to sell roll bars and have no interest in making profits from selling OEM panels. As such, we are aligned with our prospective customers in that we want to keep panel costs and shipping as low as possible - all of which may add to the attractiveness of our roll bar solution.

In summary: We will provide an option to order panels from us and pre-modifying them is the least of our concern. We DO have concerns about shipping costs. We still have work to do to determine the amount of mods and best methods for the DIY'r to achieve. We would like to make this as easy as possible - potentially enabling you to purchase/obtain your panels locally. The good news here is that the panels are hardly unique. To the best of my knowledge, they are NOT unique to the Boss and there's probably a LOT of current gen Mustang models that share this panel. As such, they are hardly a "treasure" and should be easily obtainable many, many years into the future.

The other interior mod will be where the support tubes transition into the trunk. We tried to be as smart as we could in lessening panel mods when we came up with our design. The horizontal sheetmetal rear shelf (that houses your rear speakers) comes forward and then has ~4" vertical lip on it. The LS cross brace attaches to this lip and the Boss rear seats have a latch on this lip. Our support tubes transition to the trunk just below this lip. The design objective was 1) to avoid making any cuts in this sheetmetal and; 2) get as close as we can to this lip.... thus enabling LS owners the ability to "notch" the upper edge of their trim panel instead of cutting a hole. Frankly speaking - I still don't know what mod is required here. I will have more info and pics soon. After all... if you're still reading this there's no denying that you ARE ANAL!

Aside from the minor interior trimming/mods that will be needed, the other question was what holes/cutting/sawing must be done for installation. Again, we've tried to make this as easy and least intrusive as possible! There will be 4 holes total that will need to be drilled - and you won't even need a template to make them. In the trunk and around the rear shock towers, you will see that Ford uses double-wall sheetmetal as reinforcement. The sheetmetal layer on the trunk side and easily visible to you has a couple of holes in it - but the sheetmetal layer that it sandwiches against doesn't have these holes. We will have you drill out the holes through the second layer of sheetmetal - 2 holes per shock tower and this is where we will have you bolt in the shock tower brace along with momentarily dropping the top of the shock to use it as an additional attachment point for the brace. That is the totality of drilling/cutting that you will do. Everything else is complete bolt-in.

Sorry for the long post. As I say way too often...... "more soon".

Jza1736 1/11/12 01:02 PM

"anxiously" waiting :)

ulev1st 1/11/12 05:12 PM

Man, Kendall.....this just makes me anxious to get it!

RJorge1950 1/11/12 05:16 PM

Can't wait to see the finished bar on your car !
I fully understand about the shipping costs.

P.S. Don't forget the seatbelt kit

Rob

nota4re 1/11/12 05:35 PM


P.S. Don't forget the seatbelt kit
We're working on that. I just recieved some pieces to try. The objective is to have harnesses ready when the bars are. Trying to get a little bit of "Boss 302" customization on the belts/latch.... enough to entice you to consider our harness compared to many others that are available.

Jza1736 1/11/12 05:38 PM


Originally Posted by nota4re

We're working on that. I just recieved some pieces to try. The objective is to have harnesses ready when the bars are. Trying to get a little bit of "Boss 302" customization on the belts/latch.... enough to entice you to consider our harness compared to many others that are available.

I'm enticed already, quit teasing us ;)

MrGT5oh 1/11/12 08:39 PM


Originally Posted by 5 DOT 0 (Post 6220423)

Too funny!

I love it!

Maybe Mary Kay will sponsor a BOSS for me.:heh:

MrGT5oh 1/11/12 08:54 PM


Originally Posted by nota4re (Post 6220424)
Anal owners unite!!! (I'd like to think I am one too!!)

Let me address the questions.

Regarding the panels. There are two reasons that people may want the panels from us. One, getting new panels will allow the owner to retain his/her existing panels in their virgin OEM form. Second, getting panels from us that are "pre-modified" will aid in the installation process - less for the customer to do. Obviously, many prospective customers would say yes to both reasons.

I purchased a pair of these panels with the intention of confirming 1) that I got the right panels and; 2) what the packaging was. The good news is that I did indeed get the right panels and the bad news is that the boxes are very large. Our challenge is in packaging/shipping and how do we achieve this in the most economical way. We are still looking at that. Additionally, we are looking at the "degree of difficulty" of the panel mods that would be needed and how easily the average DIY'r could do these mods themselves. Just to be completely transparent - we seek to sell roll bars and have no interest in making profits from selling OEM panels. As such, we are aligned with our prospective customers in that we want to keep panel costs and shipping as low as possible - all of which may add to the attractiveness of our roll bar solution.

In summary: We will provide an option to order panels from us and pre-modifying them is the least of our concern. We DO have concerns about shipping costs. We still have work to do to determine the amount of mods and best methods for the DIY'r to achieve. We would like to make this as easy as possible - potentially enabling you to purchase/obtain your panels locally. The good news here is that the panels are hardly unique. To the best of my knowledge, they are NOT unique to the Boss and there's probably a LOT of current gen Mustang models that share this panel. As such, they are hardly a "treasure" and should be easily obtainable many, many years into the future.

The other interior mod will be where the support tubes transition into the trunk. We tried to be as smart as we could in lessening panel mods when we came up with our design. The horizontal sheetmetal rear shelf (that houses your rear speakers) comes forward and then has ~4" vertical lip on it. The LS cross brace attaches to this lip and the Boss rear seats have a latch on this lip. Our support tubes transition to the trunk just below this lip. The design objective was 1) to avoid making any cuts in this sheetmetal and; 2) get as close as we can to this lip.... thus enabling LS owners the ability to "notch" the upper edge of their trim panel instead of cutting a hole. Frankly speaking - I still don't know what mod is required here. I will have more info and pics soon. After all... if you're still reading this there's no denying that you ARE ANAL!

Aside from the minor interior trimming/mods that will be needed, the other question was what holes/cutting/sawing must be done for installation. Again, we've tried to make this as easy and least intrusive as possible! There will be 4 holes total that will need to be drilled - and you won't even need a template to make them. In the trunk and around the rear shock towers, you will see that Ford uses double-wall sheetmetal as reinforcement. The sheetmetal layer on the trunk side and easily visible to you has a couple of holes in it - but the sheetmetal layer that it sandwiches against doesn't have these holes. We will have you drill out the holes through the second layer of sheetmetal - 2 holes per shock tower and this is where we will have you bolt in the shock tower brace along with momentarily dropping the top of the shock to use it as an additional attachment point for the brace. That is the totality of drilling/cutting that you will do. Everything else is complete bolt-in.

Sorry for the long post. As I say way too often...... "more soon".

Thanks for the detailed information. I didn't realize that the panel were so large. Knowing that now I will most likely elect to source the panels locally and use your directions for modifying the panels.

I'm looking forward to seeing the finished product.

Afdharley 1/12/12 09:04 AM

So the side panel only needs a notch cut in the back?

I was looking at the bar from MaxMo and they require the panel to be cut in half, I'm hoping yours doesn't go that far.

nota4re 1/12/12 12:15 PM


So the side panel only needs a notch cut in the back?

I was looking at the bar from MaxMo and they require the panel to be cut in half, I'm hoping yours doesn't go that far.
"MaxMo" rear braces attach to the wheel well sheetmetal. Our rear braces are significantly more "in-board" and do not require any modification to the side panels. The side panel modification is solely the mods needed for the foot of the main hoop (on each side). Hope that helps.

Afdharley 1/12/12 01:53 PM


Originally Posted by nota4re (Post 6221501)
"MaxMo" rear braces attach to the wheel well sheetmetal. Our rear braces are significantly more "in-board" and do not require any modification to the side panels. The side panel modification is solely the mods needed for the foot of the main hoop (on each side). Hope that helps.


So you're saying just a notch at the floor where main hoop attaches. I like that much better.

I'm still in for one, just have to wait till my wife gets her retirement check sorted out.

Ice Hawk 1/12/12 11:08 PM

Wow. This is the best read I've ever read about a roll bar installation. You have successfully made a technical article into an interesting read! I'm quite excited about the potential for your bar and harness. I can't wait to order my 13 Boss. :D

nota4re 1/13/12 08:09 AM


Wow. This is the best read I've ever read about a roll bar installation. You have successfully made a technical article into an interesting read! I'm quite excited about the potential for your bar and harness. I can't wait to order my 13 Boss.
And you, sir, make sure you get your *** back over here safe and sound after serving our great Country. PM or email me when and if you ever are interested in a product from us! Take care.

nota4re 1/26/12 08:15 AM

I picked the first roll bar up last night!! Off to powder coating today! I have a week-long biz trip next week but expect to have some "FINISHED PRODUCT" pics next weekend. FINALLY!

Jza1736 1/26/12 09:30 AM

Impatiently waiting :)

Afdharley 1/26/12 11:32 AM

Awesome! Can't wait.

RJorge1950 1/30/12 12:12 PM


Originally Posted by nota4re (Post 6235051)
I picked the first roll bar up last night!! Off to powder coating today! I have a week-long biz trip next week but expect to have some "FINISHED PRODUCT" pics next weekend. FINALLY!

Have a safe trip Kendall!

Rob

nota4re 2/2/12 07:06 AM

1 Attachment(s)
Looks like we nailed the color....

(Cool Tech Roll Bar pictured with OEM LS cross brace.)

Attachment 100645

Jza1736 2/2/12 09:56 AM

Looking good!

Dean#4AI 2/2/12 10:48 AM

Beautiful!!

RJorge1950 2/2/12 01:30 PM

Kendall you didn't just nailed it you hit it out of the ballpark !

The pipe clamps look awesome. I don't see the seatbelt centering brackets, did you decide not to use them ? The bar is going to look great with black seat belts with some red Boss Logos on them, can't wait to see them. When can we expect them to be on the Cool Tech website ? Hope you are having fun on your business trip.

Rob

ulev1st 2/2/12 08:15 PM

Man that is SWEEEEEEET! Just waiting for the word mine is ready!

smbstyle 2/2/12 08:40 PM

cant wait to see a comp orange painted rollbar in a C/O Boss.... :drool:

2 Go Snake 2/2/12 09:46 PM

Bars look really good painted. Can hardly wait to see pictures after final installation. :nice:

cloud9 2/3/12 08:29 AM

1 Attachment(s)

Originally Posted by smbstyle (Post 6242018)
cant wait to see a comp orange painted rollbar in a C/O Boss.... :drool:

I considered it, but thought it would be too much. I decided to follow the roof and interior color. I'd be curious to see one though if someone decides to do it.

Jimmy Pribble 2/3/12 09:07 AM


Originally Posted by cloud9 (Post 6242277)
I considered it, but thought it would be too much. I decided to follow the roof and interior color. I'd be curious to see one though if someone decides to do it.

I am also against "too much" in my street car, but since I have KB, I think that would be the bee's knees to have the bar painted KB. A little flair, but not too much...maybe just right.

Jimmy

nota4re 2/3/12 09:28 PM

3 Attachment(s)
Got back from my trip and jumped in on getting the roll bar installed.

Attached are some first pics. Notice the strategic location for the pass-thru to the rear strut brace... This location requires only a notch in one panel. Fitment has been amazing. (The side panels shown are the prototypes and the production templates will have you leave more material for a tighter fit. We'll share pics when we do the next install!!

Going to bed...

Attachment 100749

Attachment 100750

Attachment 100751

Apollo 2/3/12 11:12 PM

WOW!!! NICE...:nice:

I know you have a few more surprises to come to supplement the roll bar...;) but I won't tell.


Originally Posted by nota4re (Post 6243036)
Got back from my trip and jumped in on getting the roll bar installed.

Attached are some first pics. Notice the strategic location for the pass-thru to the rear strut brace... This location requires only a notch in one panel. Fitment has been amazing. (The side panels shown are the prototypes and the production templates will have you leave more material for a tighter fit. We'll share pics when we do the next install!!

Going to bed...

Attachment 100749

Attachment 100750

Attachment 100751


GT_350 2/4/12 12:13 AM

Looks GREAT!:)

Jza1736 2/4/12 02:47 AM


Originally Posted by nota4re
Got back from my trip and jumped in on getting the roll bar installed.

Attached are some first pics. Notice the strategic location for the pass-thru to the rear strut brace... This location requires only a notch in one panel. Fitment has been amazing. (The side panels shown are the prototypes and the production templates will have you leave more material for a tighter fit. We'll share pics when we do the next install!!

Going to bed...

<img src="https://themustangsource.com/attachment.php?attachmentid=100749"/>

<img src="https://themustangsource.com/attachment.php?attachmentid=100750"/>

<img src="https://themustangsource.com/attachment.php?attachmentid=100751"/>

Looks sweet! Is that the oem crossbrace? Will that be part of the setup or something we will have to get on our own?

yankee_pony 2/8/12 10:12 AM

Can we please have a picture of the instaled RB from inside the trunk area.

2 Go Snake 2/8/12 11:17 AM

The final installation looks perfect. Every Boss LS subjected to track use should have a set of those bars ! :p

Afdharley 2/8/12 11:33 AM

I want one in Comp Orange!

2006mach1 2/8/12 02:51 PM


Originally Posted by yankee_pony (Post 6246931)
Can we please have a picture of the instaled RB from inside the trunk area.

Check out there website as it shows the picture you want. I beleive it also tells about the suprise to supplement the rollbar.

Jimmy Pribble 2/8/12 04:02 PM

This is SO nice! Sigh. There goes the baby seat. Sorry kid. :baby:

Question: would a custom color be powder coated only, or is painting an option? The only reason I ask about painting is because it might be hard to color match the factory colors if powder coating is the only option.

Jimmy

GT_350 2/8/12 05:53 PM

Just ordered mine..............

nota4re 2/8/12 07:09 PM


Question: would a custom color be powder coated only, or is painting an option? The only reason I ask about painting is because it might be hard to color match the factory colors if powder coating is the only option.
Let me know what color you are interested in and we can see if we can have a match. We currently have orders in for Competition Orange and we are seeing if we can do that. If we can't match it with powdercoat, I'd suggest that you order the bar unfinished and get it painted locally upon receipt.

Jza1736 2/8/12 07:26 PM


Originally Posted by nota4re

Let me know what color you are interested in and we can see if we can have a match. We currently have orders in for Competition Orange and we are seeing if we can do that. If we can't match it with powdercoat, I'd suggest that you order the bar unfinished and get it painted locally upon receipt.

Will you be able to match the Kona?

phiggs54 2/8/12 07:43 PM


Originally Posted by Jza1736

Will you be able to match the Kona?

I wonder how a Performance White bar would look in the KB Boss?

Jza1736 2/8/12 07:45 PM


Originally Posted by phiggs54

I wonder how a Performance White bar would look in the KB Boss?

That's my second choice ;)
I ordered mine today. Just waiting on them to contact me about the custom color!

steveespo 2/8/12 07:59 PM

How much? What is the lead time?
Steve

GT_350 2/8/12 08:23 PM


Originally Posted by steveespo (Post 6247493)
How much? What is the lead time?
Steve

http://www.cooltechllc.com/Boss/Boss_Roll_Bar.shtml

$1,595.00 = shipping

Only says first come first served...............

RJorge1950 2/8/12 09:22 PM


Originally Posted by GT_350

http://www.cooltechllc.com/Boss/Boss_Roll_Bar.shtml

$1,595.00 = shipping

Only says first come first served...............

I came already !

AlsCobra 2/8/12 09:23 PM


Originally Posted by RJorge1950

I came already !

TWSS :D

GT_350 2/8/12 09:38 PM


Originally Posted by RJorge1950 (Post 6247623)
I came already !

bow chicka bow wow

RJorge1950 2/8/12 10:21 PM

Hi GT 350,

What color did you get ?
Since I have the LS I got the red.
Good luck with your bar, hope we never have to use it.

Rob

ulev1st 2/9/12 04:40 AM

Placed my order for a red one....hope I got in before the cutoff.


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