This winter when I was off work I finally installed my custom RLR roll bar. Needless to say, it was a huge PITA. One reason was that I have my oil cooler mounted under the rear of the body right where one of the rear bars is suppeosed to mount. I ended up drilling a hole through the mounting plate of the bar and running the mounting stud for the cooler through the floor and then through the mounting plate. Sounds easier than it was to get everything lined up. The other major PITA was that one of the reinforcement plates that go under the pan interfered with the step in the pan. I had to "stretch" 3 of the holes in that plate to get everything to clear and mount up. The other 5 plates fit perfectly.
Hole stretching on my mill.
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Rear bar with oil cooler mount stud going through it.
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Since I mounted the bar under the carpet, I was left with ugly trimmed carpet where the bars went through it.
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3D printing to the rescue! I designed these trim pieces for the 6 locations the bar goes through the carpet. They interlock on one side and use a small screw on the other.
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After designing, printing, and test fitting all 6, I painted them ivory to match the knobs and other trim pieces in the car
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And finally, all mounted. Looks much better than ratty carpet edges i think.
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Another small project that i just did today was to design and print a horn button. I used the dual extruder capabilities of my printer to print it in one piece with two colors. A little sanding and plastic polish and it looks pretty decent. I'm happy with it at least.
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