So things have slowed a little on Sunshine as one of the tasks I must sort is ensuring that we can duplicate everything I do on all the other Manxter 2+2 kits. This will mean all the customers get a bolt together solution but it also means that it takes more time to do it.
One of the major areas of concern with the Manxter 2+2 kit and getting compliance in Australia was with what Meyers Manx USA call the roof support system. It does not ship with any sort of seat belt mounts and the design and material used is not legal in Australia.
So we need to change this. The Australian Manxter 2+2 kits will all have roll bars which are CNC Bent from 1020 grade CDW Tube at 44.45 OD(1/3/4) with a 2.6mm wall. Meyers Manx USA do offer a 1020 grade upgrade on their barwork but it was still undersized for Australian use. Now some states such as Queensland call for a minimum OD of 45mm in the main hoop. We have been allowed to use 44.45 by increasing the grade of tube and gaining engineer approval. As far as seat belts go we will be fitting several compliant seatbelt boss kits to the main and rear hoops. Along with all this is the increase of the mounting plate and fasters to comply as well as the chassis ( floor pan ) mounting points and an additional upright support to remove the issues with the bent main hoop upright.
So with all the in mind it sounds simple enough until you realise the roll cage OD is very important to the roof fitment as well as fitting in the body and it also needs to clear the dash and a few other points.
Ah the fun of building approved cars ...
Luckily for me I have Dave onside and he will make the mods and enhancements look sweet and hopefully be very hard to pick without us telling you. The style of the Manxter Cage is one of the defining features of the Manxter and something I am very keen to retain.
I must say though after playing around with it for a few hours yesterday I will be VERY happy to put my wife and kid into it. After working on a lot of different buggies and barwork setups I am very happy with the way it all ties in and not only compliments and reinforces the body but looks and feels very safe.
So stage 1 was to get the bits of barwork we got from Meyers Manx USA assembled and tacked out in the body, brace it all up and then start building a jig to suit the OD of the factory bars.
Then we work backwards to build our new bars.
Even sitting naked the skeleton looks sexy ....