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Old 10-25-2005, 01:35 PM   #1 (permalink)
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Formula offroad, cage and chassis design...

Ok all you guys(girls?) on the other side of the pond. Time for some tech.

You guys arguably see the hardest hits and most severe off road rollovers out there, although maybee onto more forgiving ground. But every time i watch a vid, or look at a pic, I cant help but think to myself that your cages seem very inadaquate, yet always hold up.

I look at the cages i design and build and theres a shitton more tube in them. I think that if i were to build a chassis or cage to hold up to the abuse that you guys would dish at it, it's be heavy as all get out.

How many HARD rolls do you get out of a chassis or cage?

What kind of materials are the norm over there?

What kind of chassis/cage failures do you see? Have pics of failures?

Any good links on full buildups of any of your cars so we can see the actuall structure of the chassis under the skins?

I just cant help but think that we over here are just tremendously overbuilding stuff, when i see you guys drop a rig from 20' onto the corner of a realtivly simple cage, and it seems to be still in great condition.

to the biggest balls in the offroad world.
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Old 10-25-2005, 01:52 PM   #2 (permalink)
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We don't do vertical in mud, but I did see this guy take a HARD multiple roll at one of my events in 2002 & not tweak the chassis at all. Body was toast, as you'd expect.






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Old 10-25-2005, 03:04 PM   #3 (permalink)
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Quote:
Originally Posted by sceep
I just cant help but think that we over here are just tremendously overbuilding stuff,
I'd hate to say I told you so...

Well. For 1. the formula offroad rigs usually land on sand, or soft dirt. The impacts will very rarely be as hard as some of the rockcrawling rolls I've seen in videos.

2. IMO, you americans seem to have this "thing" that you have to go crazy with the bender. Yes, triangulation is good. But you don't need to triangulate every f'in square inch I agree that a lot of it looks really good. And a lot of it looks just like somebody went crazy with a bender... w/o the cage necessarily being much stronger.

Our rules from building cages (I am now talking about Trials competitions, Norwegian rules) is based on the same layouts as rally car cages. And they can take a lot.

Here is one suggested layout from the rules book (trials)


and here are two from Formula



The minimum tubing requirements I believe is 45mm OD x 2mm wall, DOM/"seamless", and ST35 yield strength. I don't know if the req's for Formula Offroad is higher, but I believe the steel is the same but they demand a few more diagonals, and better mounting to the body/chassis. A lot of us (including me & mr. Rustan) use 48.3mm OD, 2.6mm wall & ST52 strength. (Can somebody calc these into US notations?)

Here is some pics of Rustan's buildup: http://www.rustanmotorsport.no/Ny%20...05/index1.html

Pics of his rig here, http://www.rustanmotorsport.no/pictures.htm very cool looking rig!
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Old 10-25-2005, 03:08 PM   #4 (permalink)
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Quote:
Originally Posted by Amund
Here is some pics of Rustan's buildup: http://www.rustanmotorsport.no/Ny%20...05/index1.html
Is rust part of the spec.s too?
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Old 10-25-2005, 03:12 PM   #5 (permalink)
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those lower 2 cages will hold up and protect you (assuming driver is seated correctly away from the apillar fold.)

and it must be the sand..I think that those cages wouldd hold up fine but longevity would be severly short in rockcrawling.

also some of the reason you see so much triangulation in ours is that, the trend is 1.5 or 1.25 inch tubing..to make it light, then add lots of triangle to make it rigid.

race or highspeed design dictates a different approach then landing on one tiny peice of yoru chassis, on a very hard object
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Old 10-25-2005, 03:19 PM   #6 (permalink)
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Quote:
Originally Posted by TEX





TEX
In no way is that a simple cage.....That's Nascar like around the driver. Not the point or the thread. Hell, I'd jump that fawker!!
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Old 10-25-2005, 03:19 PM   #7 (permalink)
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Yall remember this vid of testing a simple cage in a bronco by rolling it down a hill a few times?

Click for vid.

Held up pretty good for only having ONE front down tube.

Discuss.
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Old 10-25-2005, 05:04 PM   #8 (permalink)
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40mm = 1.57"; 2mm = 0.079". That's pretty light stuff.
48.3mm = 1.9"; 2.8mm = 0.11".

I don't know what the ST numbers translate into in US specs.

Common American cages are 1.5"x0.120 in many competition cars, 1.75"x0.120 in some comp and many trail rigs, and 2"x0.120 in large heavy trail rigs and some buggies.

For reference, 1.5" = 38.1mm; 1.75" = 44.45mm; 2" = 50.8mm; 0.120" = 3.05mm.

So we're building stuff quite a bit heavier than you guys are. My current comp rig is 4130 chromoly tube throughout, some 1.5x0.120, some 1.5x0.095 (38.1x2.4mm), and some 1.25x0.083 (31.75x2.1mm). I wouldn't realistically consider less than 1.5x0.095 4130, or 0.120 DOM, for a cage.

I agree with Sceep--if you crash, how bad do you have to crash, and/or how often, before you have to either build a new car, or at least a new cage? Normally, stateside, a comp rig usually lasts a year or two, while a trail rig many years, without even significant tubework (although some comp rigs require regular tube replacement on the really lightweight vehicles).
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Old 10-25-2005, 10:48 PM   #9 (permalink)
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no picture of the immediate "after", and this looks like it was cut off to remove the injured driver - but it also looks like maybe not enough over-building in that rig?. My apoligies if it doesn't apply to this discussion.

Last edited by deepmud; 10-25-2005 at 10:50 PM.
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Old 10-25-2005, 11:28 PM   #10 (permalink)
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The cage was still protecting the space after that landing - Per had some back injuries and the cage was cut off to extricate him properly...

That is not a cage failure - just a really big flat hit from way over shooting a lip...




Last edited by wanderingwillys; 10-25-2005 at 11:32 PM.
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Old 10-26-2005, 12:09 AM   #11 (permalink)
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Regarding steel types / qualities

St52 = DIN-EN 10 027-1 S355GT
max 0,22% C
max 0,55%Si
max 1,6% Mn
Depending on condition it has a yield stress of min 355 MPa (N/mm2) (is what? 51488psi?
UTS 490-630 MPa
Elongation A5 22 to 4% depending on how much cold work is done

St35 = DIN-EN 10027-1 S235G2T
max 0,17% C
max 0,35%Si
min 0,40% Mn
YS min 235MPa (34083psi?)

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Old 10-26-2005, 01:14 AM   #12 (permalink)
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The Swedish rules say 45x2.5mm or 50x2.0mm tubing in formula offroad.
The main hoop also needs be in one peice. I think that's where most US rig would fail in a trail or formula offroad tech inspection.
Is it stronger or weaker to have a hope in one peice compared to something like this?
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Old 10-26-2005, 05:24 AM   #13 (permalink)
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In the UK, where our cage designs are based on FIA requirements, and are similar to the Formula cars in design, you can either use continuous tubes from side to side behind the driver (main hoop) and at the windscreen (front hoop), or down either side of the car (front ot back), or across the car behind the driver and down the sides from the windscreen to the main hoop. What is essential is the triangulation of the cage. I always do a X in the rear hoop and usually a X in the roof joining the Main and front hoop, plus side bars (IXI), which prevents the front hoop moving sideways if you have a big hit on one corner.

I've seen cars that have had multiple rolls at 40/50 mph on fairly hard ground (dry fields/dirt tracks) with little or no deformation. I've also seen cars without the X brace in the roof completely destroyed due to lack of triangulation.

For info, we use 1.5" NB (48.3 mm Dia) gas pipe which the equivalent of Sch 40 I think for most of our off road cars, and our club scrutineer prefers it as he has seen too many DOM cages shear at welds with excessive deformation.
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Old 10-26-2005, 09:45 AM   #14 (permalink)
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Quote:
Originally Posted by sceep

Any good links on full buildups of any of your cars so we can see the actuall structure of the chassis under the skins?

I just cant help but think that we over here are just tremendously overbuilding stuff, when i see you guys drop a rig from 20' onto the corner of a realtivly simple cage, and it seems to be still in great condition.

to the biggest balls in the offroad world.

Our Willyster build up here:

/forum/general-4x4-discussion/98946-our-new-one-coming-up.html
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Old 10-26-2005, 09:49 AM   #15 (permalink)
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Some rules that are not yet 100% sure for 2006, but are very very close to that.


Technical regulations Formula Offroad


APPEDIX A

Nitrous Oxide

·Only complete systems from reputable manufacturers installed according to instructions are allowed.
·Nitrous bottle must be securely mounted with two steel bands of at least 2,5x25mm completely circling the bottle.
·Nitrous bottle can not be installed in the engine compartment.
·Nitrous bottle must be installed with the valve end pointing away from the driver or have a shield protecting the driver from a valve blowoff made of 2mm steel or 4mm aluminium plate.
·Nitrous bottle must be installed in such a way that it is protected from outside impact in case of a rollover.
·All nitrous hoses must be able to handle at least 3000psi.
·All nitrous hoses must be securely fastened.
·Electrical system for nitrous:

1.Circuits can not be “-“ switched.
2.It should not be possible to switch system on unless ignition is on.
3.The system must have a separate arming switch clearly marked NOS on/off.
4.The system should only be possible to activate at WOT throttle position.
5.The system should only be possible to activate above 2000 engine rpm.
6.A fuel pressure safety switch must be installed to disable the system if fuel pressure to system falls below 5psi.
·Closed vehicles must have a FIA/SFI approved fire extinguishing system installed with at least one nozzle aimed at the driver and one aimed at the engine.
·FIA warning sign for NOS – Green square with white lettering must be on the back of vehicle.
·Bottle warming system must be from a reputable manufacturer and installed according to instructions.
·Nitrous pressure gauge must be installed if bottle warming system is used.


APPENDIX B

Rollcage

·All vehicles must have a six point rollcage mounted directly to the frame or chassis structure that connects all six points.
·Rollcage must be designed to protect the driver from all sides.
·Seamless Steel tubes of at least 350 N/mm2 must be used. Aluminum or Chromemoly Steel is not allowed.
·Tube size must be minimum 2,5 x 45mm alternatively 2 x 50mm.
·Vehicles that do not presently have the minimum size/quality tubing in the rollcage will only be allowed to compete until 31.12.2006. After this time the rollcage must be replaced to comply with current specifications.
·No tube bends may be smaller than 3 x the tube diameter.
·All welds must be high quality. Grinding of the welds is not allowed.
·Minimum requirements of design (refer to schematic drawing):

1.One piece main rollbar installed from side to side of vehicle.
2.One piece front bar installed from side to side or one piece side bars with front bar connecting the two.
3.Rear braces from rear top corners to back of vehicle in minimum 30 degree angle.
4.Diagonal cross braces in main rollbar or in rear braces. (For vehicles licensed after 01.01.2006 it must be in the main rollbar)
5.If rollbar width is more than 100cm: Vertical bar from top center of rear rollbar to meeting point of cross braces.
6.“V” or “X” bars in roof of rollcage.
7.Tubes connecting front and rear rollbar. Preferred location is as low as possible in front bar and mid height in the main rollbar.

·Roof plate mounted on top of rollcage:
1.1mm steel plate securely welded in place,
or
2.2mm steel plate bolted in place with M8 bolts of 8.8 grade no more than 50cm apart,
or
3.3mm aluminium plate bolted in place with M8 bolts of 8.8 grade no more than 50cm apart.
4.For bolting of plate mounting brackets must be welded to rollcage. No drilling allowed in rollcage.

·For vehicles licensed after 01-01-2006:
1.Minimum size of roofplate is 0,75 m2
2.Minimum width of rollcage is 100cm.
3.Minimum distance from center of driver seat to outer edge of rollcage is 40cm.
4.Tube connecting left and right side of main rollbar mounted as low as possible in the chassis.
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Old 10-26-2005, 09:53 AM   #16 (permalink)
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Rules for Modified class cars (this class used to be called Standard)

MODIFIED CLASS

APPROVED VEHICLES
All vehicles must have two axles and four wheel drive.
All vehicles must have a bodyshape that resembles a mass produced vehicle.
All vehicles licensed after 01012006 must have two seats installed side by side.

1. Chassis
1.1 Frame and chassis structure.
The main frame structure must be constructed of: (applies only to vehicles licensed after 01.01.2006)
·Original frame from a mass produced 4x4 vehicle,
or
·Seamless steel tubing of minimum size 45x2,5mm or 50x2mm (350 N/mm2), or
·Square tubing of minimum size 40x60x3mm (350 N/mm2)
Aluminum or Chromemoly steel is not allowed.

2. Wheels and suspension
2.1 Tires
Paddle tires type “Multipaddle” or “Padla Trak” are allowed.
All types of tires approved for street use is allowed. It is not allowed to custom groove resurfaced tires.
Snow chains or any kind of attachments to improve traction is not allowed.

2.2 Wheels
Free of choice.

2.3 Suspension
Free of choice.
Active, adjustable suspension is not allowed in competition.
For vehicles licensed after 01.01.06 properly mounted bumpstops of gas charged hydraulic design is mandatory.
This is also highly recommended for older vehicles.


2.4 Shock absorbers
Free of choice

3. Drivetrain
3.1 Engine
Free of choice.
Supercharger(s), Turbocharger(s) and Nitrous Oxide are allowed.
For roots type superchargers a shield made of 1,5mm steel or 2,5mm aluminium must cover the drive belt. The shield must be securely mounted to the engine or chassis. Any fuel, nitrous or oil hoses nearby the drive belt must be enclosed in steel pipe or be of a steel reinforced type. SFI approved limiting straps must me installed in case of a supercharger blowing off the manifold. All fuel hoses must be long enough as to not break in such a case.
Harmonic balancer (if so equipped) and flexplate/flywheel must be of racing type.
Dual, correctly working return springs must be installed on the carburettor/throttle body.

3.2 Fuel system
Fuel tank must be designed for racing and securely fastened. It must not be installed in the driver compartment. There must be a wall to prevent fuel leaking into the driver compartment in case of a rollover. The fuel cap must be leak proof and a check valve must be installed in the vent hose.
All fuel lines must be one-piece and securely fastened. Any fuel lines passing through the driver compartment must pass through a steel tube of 1mm thickness with a diameter of 2 times the diameter for the fuel line.
Diesel, Bio Diesel, Gasoline and Racing gasoline is allowed.
Lead substitute and Octane booster is allowed. All other fuel additives are banned.
Water injection is allowed. Propane (LPG) injection is not allowed.
Nitrous oxide is allowed if installed according to appendix A.
Methanol fuel is allowed if the vehicle is clearly marked front and rear with “METHANOL FUELED” in a yellow square 15x30cm and has a FIA approved fire extinguishing system installed in the vehicle with at least 3 nozzles towards the engine and 2 nozzles in the driver compartment.


3.3 Cooling system
Radiator and overflow tank is not allowed the driver compartment. All hoses must be undamaged and of high quality.
Any hoses or tubes passing through the driver compartment must be covered and without splices.

3.4 Exhaust system
Free of choice. Noise level can not exceed 110dB according to FIA measurement rules.

3.5 Electrical system
Battery must be of dry cell design and securely mounted with upper and lower brackets. The positive battery post must be securely covered with a non conductive material.
All cables must be securely fastened.
An electrical master switch must be installed in reach of the driver when sitting with the seatbelts tightened. A second switch or a wire actuating the primary switch must be installed in the rear of the vehicle. The rear switch or release handle must be clearly marked with a blue triangle and a red lightening inside the triangle.

3.6 Transmission and drive shafts
Free of choice. Automatic transmissions must have a properly working neutral safety switch and a flexplate/transmission shield made from 6mm thick steel plate or SFI approved.
Transmissions with a SFI approved bellhousing do not need these shields.
Vehicles with manual transmissions must have the starting current wired through a brake light switch.
Front and rear driveshafts must have a safety loop made of 5x50mm steel or 21x1,5mm steel tube bolted to the chassis or transfer case with minimum two grade 8.8 M10 bolts. The safety loops must be on the transfer case end of the drive shafts.

4. Brake system
4.1 Regular brakes
Free of choice, but must be operated by foot, positively work on all four wheels and capable of locking up all four wheels simultaneously.
Driveshaft mounted brakes are not allowed.
4.2 Parking brake
Properly working handbrake and/or park function in transmission must be installed.
4.3 Brake lines
All brake lines must be undamaged and securely fastened.
4.4 Steering brake
No form of steering brake system is allowed.

5. Steering system
5.1 Steering parts
The vehicle must be controlled by a conventional steering wheel mounted in front of the driver. Hydraulic steering and all types of conventional steering from vehicle manufacturer are allowed. All steering components must be well dimensioned for safe control of the vehicle at all times. All hydraulic hoses except for the drain hose must have pressed-on ends, be free of any damages and have sufficient length to allowfull movement of the suspension.
All steering hoses must be protected from potential damage caused by engine or suspension components. All hoses connected to the orbitrol must be shielded from the driver.
Minimum diameter of the steering rod in hydraulic cylinder is 22mm.
Four wheel or mid-chassis steering is not allowed.

6. Body
6.1 Bodyparts
The bodyshape must resemble a mass produced vehicle. The length of the body must cover the wheelbase of the vehicle. Hood, side body panels, front and rear fenders must be installed and resemble the original vehicle.
Engine air intake protruding through the body must be designed to protect the driver from direct blowback from the carburettor/throttle body.
Any windows must be made of laminated glass or polycarbonate/lexan.

6.2 Driver compartment
Walls separating the driver’s compartment from the engine, oil coolers and radiator must be installed. The purpose is to prohibit fluids and/or flames spreading.
If the engine air intake is in the driver’s compartment it must be baffled to protect the driver from any blowbacks.
If the driver does not use armstraps a window net with maximum 50mm web size and minimum 2mm thread size must be securely installed.
The distance from the top of the driver’s helmet to the top of the rollcage must be at least 10cm.

6.3 Floor
Floor of the vehicle must be made of 1mm steel or 2mm aluminium and completely cover the whole floor. If the front driveshaft passes under the driver seat, the material in this area must be at least 2mm steel or 3mm aluminium.

6.4 Drivers seat
Seat must be of racing type and have holes for a 5 point seat belt.
Seat must be securely fastened and the back of the seat must rest against the rollcage or braced in a similar way. If the seat is mounted on a sliding bracket, there must be an extra safety pin installed to prevent sliding of the seat.

6.5 Rollcage
6-point rollcage according to appendix B mounted directly to the frame must be installed.

6.6 Seatbelts
Only 3” wide FIA/SFI approved seat belt with 5 or more fasteners is approved.
Seat belt must be undamaged and must be within approved date markings.
Shoulder straps must be installed in line with the drivers shoulder or lower such that the angle between the back of the seat and shoulder straps is between 45 and 90 degrees. If the seat belt is installed using bolts the bolts must be minimum M10 bolts with of at least 8.8 grade. If the bolts are installed in the bodywork, the area must be reinforced with a 2mm steel plate of at least 20cm2.
Drilling in the rollcage for mounting seatbelts is not allowed.

7. Miscellaneous
7.1 Lights
Any external lighting made of glass must be taped over during competition.

7.2 Gauges and switches
Free of choice

7.3 Towing hooks
Front and rear towing hooks or eyes with at least 35mm diameter hole must be in the front and rear of the vehicle.
There must also be similar eyes or hooks on the top of the vehicle for lifting – preferably in the balance point of the car.
Towing and lifting points must be marked in bright color to stand out.

7.4 Communication
Communication between driver and a person outside the vehicle is not allowed while the vehicle is in a track.

7.5 Weight
Minimum weight without driver is 600kg. Any extra weight must be securely fastened.

7.6 Extra equipment
Any extra equipment (flags, aerodynamic wings, etc.) must be securely fastened and must not pose as a potential hazard to the driver or spectators/officials.
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Old 10-26-2005, 09:58 AM   #17 (permalink)
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Rules for Unlimited class (this used to be called Special)


UNLIMITED CLASS

APPROVED VEHICLES
All vehicles must have two axles and four wheel drive.
Overall design of vehicle is free of choice within the following regulations.

1. Chassis
1.1 Frame and chassis structure.
The main frame structure must be constructed of: (applies only to vehicles licensed after 01.01.2006)
· Original frame from a mass produced 4x4 vehicle,
or
· Seamless steel tubing of minimum size 45x2,5mm or 50x2mm (350 N/mm2), or
· Square tubing of minimum size 40x60x3mm (350 N/mm2)
Aluminum and Chromemoly steel is not allowed.

2. Wheels and suspension
2.1 Tires
Free of choice. Tires must be made of rubber and inflated with air.
Snow chains or any kind of attachments to improve traction is not allowed.

2.2 Wheels
Free of choice.

2.3 Suspension
Free of choice.
For vehicles licensed after 01.01.06 properly mounted bumpstops of gas charged hydraulic design is mandatory.
This is also highly recommended for older vehicles.

2.4 Shock absorbers
Free of choice

3. Drivetrain
3.1 Engine
Free of choice.
Supercharger(s) or Turbocharger(s) are allowed.
For roots type superchargers a shield made of 1,5mm steel or 2,5mm aluminium must cover the drive belt. The shield must be securely mounted to the engine or chassis. Any fuel, nitrous or oil hoses nearby the drive belt must be enclosed in steel pipe or be of a steel reinforced type. SFI approved limiting straps must me installed in case of a supercharger blowing off the manifold. All fuel hoses must be long enough as to not break in such a case.
Harmonic balancer (if so equipped) and flexplate/flywheel must be of racing type.
Dual, correctly working return springs must be installed on the carburettor/throttle body.

3.2 Fuel system
Fuel tank must be designed for racing and securely fastened. It must not be installed in the driver compartment. There must be a wall to prevent fuel leaking into the driver compartment in case of a rollover. The fuel cap must be leak proof and a check valve must be installed in the vent hose.
All fuel lines must be one-piece and securely fastened. Any fuel lines passing through the driver compartment must pass through a steel tube of 1mm thickness with a diameter of 2 times the diameter for the fuel line.
Diesel, Bio Diesel, Gasoline and Racing gasoline is allowed.
Lead substitute and Octane booster is allowed. All other fuel additives are banned.
Water injection is allowed. Propane (LPG) injection is not allowed.
Nitrous oxide is allowed if installed according to appendix A.
Methanol fuel is allowed if the vehicle is clearly marked front and rear with “METHANOL FUELED” in a yellow square 15x30cm and has a FIA approved fire extinguishing system installed in the vehicle with at least 3 nozzles towards the engine and 2 nozzles in the driver compartment.

3.3 Cooling system
Radiator and overflow tank is not allowed the driver compartment. All hoses must be undamaged and of high quality.
Any hoses or tubes passing through the driver compartment must be covered and without splices.

3.4 Exhaust system
Free of choice. Noise level can not exceed 110dB according to FIA measurement rules.

3.5 Electrical system
Battery must be of dry cell design and securely mounted with upper and lower brackets. The positive battery post must be securely covered with a non conductive material.
All cables must be securely fastened.
An electrical master switch must be installed in reach of the driver when sitting with the seatbelts tightened. A second switch or a wire actuating the primary switch must be installed in the rear of the vehicle. The rear switch or release handle must be clearly marked with a blue triangle and a red lightening inside the triangle.

3.6 Transmission and drive shafts
Free of choice. Automatic transmissions must have a properly working neutral safety switch and a flexplate/transmission shield made from 6mm thick steel plate or be SFI approved.
Transmissions with a SFI approved bellhousing do not need these shields.
Vehicles with manual transmissions must have the starting current wired through a brake light switch.
Front and rear driveshafts must have a safety loop made of 5x50mm steel or 21x1,5 steel tube bolted to the chassis or transfer case with minimum two grade 8.8 M10 bolts. The safety loops must be on the transfer case end of the drive shafts.

4. Brake system
4.1 Regular brakes
Free of choice, but must be operated by foot, positively work on all four wheels and capable of locking up all four wheels simultaneously.
Driveshaft mounted brakes are not allowed.

4.2 Parking brake
Properly working handbrake and/or park function in transmission must be installed.

4.3 Brake lines
All brake lines must be undamaged and securely fastened.

4.4 Steering brake
No form of steering brake system is allowed.

5. Steering system
5.1 Steering parts
The vehicle must be controlled by a conventional steering wheel mounted in front of the driver. Hydraulic steering and all types of conventional steering from vehicle manufacturer are allowed. All steering components must be well dimensioned for safe control of the vehicle at all times. All hydraulic hoses except for the drain hose must have pressed-on ends, be free of any damages and have sufficient length to allow full movement of the suspension.
All steering hoses must be protected from potential damage caused by engine or suspension components. All hoses connected to the orbitrol must be shielded from the driver.
Minimum diameter of the steering rod in hydraulic cylinder is 22mm.
If rear wheel steering is installed, this must be operated by separate controls and must be self aligning.
Mid chassis steering is not allowed.

6. Body
6.1 Bodyparts
The length of the body must cover the wheelbase of the vehicle. Hood and side body panels must be installed.
Engine air intake protruding through the body must be designed to protect the driver from direct blowback from the carburettor/throttle body.
Any windows must be made of laminated glass or polycarbonate/lexan.

6.2 Driver compartment
Walls separating the driver’s compartment from the engine, oil coolers and radiator must be installed. The purpose is to prohibit fluids and/or flames spreading.
If the engine air intake is in the driver’s compartment it must be baffled to protect the driver from any blowbacks.
If the driver does not use armstraps a window net with maximum 50mm web size and minimum 2mm thread size must be securely installed.
The distance from the top of the driver’s helmet to the top of the rollcage must be at least 10cm.

6.3 Floor
Floor of the vehicle must be made of 1mm steel or 2mm aluminium and completely cover the whole floor. If the front driveshaft passes under the driver seat, the material in this area must be at least 2mm steel or 3mm aluminium.

6.4 Drivers seat
Seat must be of racing type and have holes for a 5 point seat belt.
Seat must be securely fastened and the back of the seat must rest against the rollcage or braced in a similar way. If the seat is mounted on a sliding bracket, there must be an extra safety pin installed to prevent sliding of the seat.

6.5 Rollcage
6-point rollcage according to appendix B mounted directly to the frame must be installed.

6.6 Seatbelts
Only 3” wide FIA/SFI approved seat belt with 5 or more fasteners is approved.
Seat belt must be undamaged and must be within approved date markings.
Shoulder straps must be installed in line with the drivers shoulder or lower such that the angle between the back of the seat and shoulder straps is between 45 and 90 degrees. If the seat belt is installed using bolts the bolts must be minimum M10 bolts with of at least 8.8 grade. If the bolts are installed in the bodywork, the area must be reinforced with a 2mm steel plate of at least 20cm2.
Drilling in the rollcage for mounting seatbelts is not allowed.

7. Miscellaneous
7.1 Lights
Any external lighting made of glass must be taped over during competition.

7.2 Gauges and switches
Free of choice

7.3 Towing hooks
Front and rear towing hooks or eyes with at least 35mm diameter hole must be in the front and rear of the vehicle.
There must also be similar eyes or hooks on the top of the vehicle for lifting – preferably in the balance point of the car.
Towing and lifting points must be marked in bright color to stand out.

7.4 Communication
Communication between driver and a person outside the vehicle is not allowed while the vehicle is in a track.

7.5 Weight
Minimum weight without driver is 600kg. Any extra weight must be securely fastened.

7.6 Extra equipment
Any extra equipment (flags, aerodynamic wings, etc.) must be securely fastened and must not pose as a potential hazard to the driver or spectators/officials.






REMEMBER THAT THESE RULES THAT I POSTED ARE NOT YET 100% APROVED FOR SEASON 2006. We are working on them at the moment.
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Old 10-26-2005, 10:02 AM   #18 (permalink)
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interesting... why no chromoly??
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Old 10-26-2005, 10:17 AM   #19 (permalink)
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Quote:
Originally Posted by kwrangln
Yall remember this vid of testing a simple cage in a bronco by rolling it down a hill a few times?

Click for vid.

Held up pretty good for only having ONE front down tube.

Discuss.
WTF????
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Old 10-26-2005, 10:32 AM   #20 (permalink)
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Regarding Chromemoly tubing:
All of our rigs are "homemade" and when it comes to welding chromemoly steel it needs to be TIG welded and preferably pre-heated. Most of us are amateurs and use MIG welders.
We have no way of checking the weld quality at the technical inspection at the races, and we sure as hell do not want any rollcages collapsing.

This is also why we have upgraded the minimum requirements for the rollgace structure for the 2006 season.

For my part, I have rolled my Formula Offroad vehicle countless times, but have only needed to replace parts of the rollcage once. This was last year in Denmark after a multipe rollover down long hill with a hard surface (not sand).
(But I have more bracing tubes than most drivers)
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Old 10-26-2005, 12:02 PM   #21 (permalink)
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Quote:
Originally Posted by sceep
interesting... why no chromoly??
From what I've heard, a chromoly cage withstands one single crash better that a DOM cage but when you plan to crash/rollover many times with the same cage like in formula offroad a DOM cage is stronger.
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Old 10-26-2005, 12:06 PM   #22 (permalink)
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from these rules and extensive searching it seems that a "halo" designed cage is not really accepted anymore? I'm talking a full circle on top and bars down from it and braced.

Are these style cages not accepted in US comps? is it a sound design or asking for trouble?
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Old 10-26-2005, 01:30 PM   #23 (permalink)
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Quote:
From what I've heard, a chromoly cage withstands one single crash better that a DOM cage but when you plan to crash/rollover many times with the same cage like in formula offroad a DOM cage is stronger.

DOM is a manufacturing process not a material type
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Old 10-26-2005, 02:06 PM   #24 (permalink)
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Quote:
Originally Posted by Amund
...... A lot of us (including me & mr. Rustan) use 48.3mm OD, 2.6mm wall & ST52 strength. (Can somebody calc these into US notations?)
[EDIT: Corrected my typos..]
St37 translates roughly into 1020 steel.
St52 translates roughly into 1040 steel.

By strength that is. Carbon, mangane etc. are added differently.
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Last edited by nose; 10-26-2005 at 02:21 PM.
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Old 10-26-2005, 02:13 PM   #25 (permalink)
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Quote:
Originally Posted by slowJEEP
DOM is a manufacturing process not a material type
I know, but I ment DOM as the mildsteel tubes commonly used in cages.
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