Safety Devices Citroen Saxo weld-in roll cage X003 fitting ... · Fitting Instructions and tips for Citroën Saxo- X003 weld-in roll cage Safety Devices International Ltd, Enterprise

Fitting Instructions and tips for Citroën Saxo- X003 weld-in roll cage

Safety Devices International Ltd, Enterprise Court, Studlands Park Avenue, Newmarket, Suffolk. CB8 7EP Tel: +44 (0) 1638 560524 Fax: +44 (0) 1638 560524 Email: [email protected] Web: www.safetydevices.com

Important Note

Roll cages must not be fitted to any car with significant rusting of the body shell near where the bar will be welded. For the main hoop this usually applies to the rear wheel arches, base of centre pillars and adjacent floor or sills and to the floor pan or sills near the front door pillars for the front cage. Furthermore, if the vehicle has ever suffered any accident damage, the body shell may be distorted and therefore may not fit the roll cage correctly. It is easier to straighten the car than modify our cage! Slight floor damage is usually simply rectified before fitting starts. The RED numbers state the part corresponding to the general assembly drawing. Please read these instructions all the way through before starting, since the order of work is important.

1. Check all the components of the kit and review the layout drawing to check the position of each part.

2. If still in place, remove from the car the following: A. The front and rear seats. B. The carpets, under felt and rear wheel arch trim where the rear cage will stand. C. All internal trim and roof lining. D. The seat belts. E. The dashboard. F. Sun visors or interior mirrors. G. Wiring Harness H. Front Windscreen I. Side windows J. Front doors K. Bonnet

3. For welding safety, disconnect the battery, remove the fuel tank, if this is not possible empty the fuel tank.

4. Fitting the hoop base plates (7), you may have to slightly modify the shape to obtain a good fit. These plates should fit into the corner of the sill and the rear seat riser. Lightly tack into position or hold in place with tape (as they have to be removed later) (See picture 1)

5. The main hoop (1) is positioned in the middle of the B post. It will need to be cut to the correct height and should be a snug fit to the side and roof of the car. If necessary dress sides of the B post to obtain a good fit. To hold the hoop in place, tape around the ‘B’ post (See picture 2)

6. Fitting the front base plates (6), you may have to slightly modify the shape to obtain a good fit. These plates fit into the corner of the sill and the inner front wheel arch. Lightly tack into position or hold in place with tape (as they have to be removed later) (See picture 1)

7. Now fit the front legs (2), these need to be cut to the right length at the front and will need to be cut to length and ground to fit the rear cage. The front cage fits in the centre of the foot plate (6). Temporarily fix in place with tape around the A post. (See picture 2)



8. To fit the front turret/triangulation tubes (20) (21), remove the wing and strengthening frame then cut the holes through the front of the bulkhead, the position of the holes can be established by looking at the front legs (2) and gauging where to cut the hole. (See picture 3).

9. The top triangulation tubes (20) can now be positioned. Cut the front end and grind the leg end of the tubes until a suitable fit is found between the turret and front leg. Now tack the triangulation tube into position but DO NOT tack to the front leg (2). The lower tube holes (21) can now be cut and lower tubes can be fitted into position, Tack the front end of the tube only.

10. With the front triangulation tubes (20) (21) in position assemble the front cage, tack the front legs (2) to the hoop (1) and fit the top screen rail (3), and roof diagonal (16) in place.

11. All the roof joints can now be welded as much as possible, DO NOT WELD the four sill plates (6) (7) to the car, OR the tubes (1) (2) to the four sill plates. (See picture 4)

12. Now remove the four sill plates (6) (7) from underneath the roll cage, This will allow the cage to be pushed off the sill one leg at a time which will give access to complete the welding around the top of the main roof joints of the roll cage.

13. After you have finished operation 12, lift the roll cage back onto the sills and push sill plates (6) (7) back underneath each leg (2), The roll cage can now be eased into the correct position contacting upper and lower triangulation tubes (20) (21). Upper door bars (18) and lower door bars (19) can now be fitted and tacked into position. Tack the foot plates (6) (7) to the shell and the legs to the plates then fully weld the whole structure including front triangulation. Stitches of weld can now be added, between 10mm to 20mm long where the cage touches the body. (See picture 8) 14. Now fit the front and rear cross door bar gussets and stitch weld. (24)

15. The tunnel brace plate (26) and the tubes can finally be fitted. (22) 16. Bolt into position the rear suspension pick up (8) and fit the backstays (into position) (5), along with the lower backstays (15), rear turret cross tube (23), rear diagonal (4), cross diagonals (13) (14) harness bars these (17) can now be fitted and tacked into position. (See picture 7)

17. When you are happy all tubes and plates are located correctly all tube joints and plates can then be fully welded.

18. You can now tack weld on the name tags (9) to the rear back stays (5).

19. Once the cage is fully welded and you are happy with the overall finish, it can now be finished to your specification. Add the homologation sticker (10) to the upper left hand B hoop (1).



Please note these pictures are for illustration purposes only. Vehicles do vary. We are always interested in updating our picture database. So please feel free to send pictures of your cage during installation to [email protected] NOTICE TO PURCHASERS

Safety Devices roll cages are a homologated design structure, therefore any alteration to the assembly by repositioning, removal or addition of fittings, drilling or enlarging of holes etc, incorrect fitment to vehicle, or use of assembly other than its design purpose, releases the producer from any and all responsibility in the event of performance failure of these goods. Remember: a roll cage is no substitute for careful and considered driving.

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Safety Devices Citroen Saxo weld-in roll cage X003 fitting ... · Fitting Instructions and tips for Citroën Saxo- X003 weld-in roll cage Safety Devices International Ltd, Enterprise