Cusco Roll Cage Tips and Safety Guidelines

There are numerous options and variations of Cusco/Safety 21 and D1 Professional Drift Roll Cages so we have put together a guide to help you answer your questions about cages and their fitment, also to help you choose the ideal roll cage for your activities.

This guide includes:

• SAFETY PRECAUTIONS and DISCLAIMERS
• Bolt in or Weld in?
• Choosing the material
• Selecting Manufacturer & Chassis Code
• Got a Sunroof?
• Choosing the C Pillar Bar Style
• The C Pillar Bar Mount Position
• How many Points?
• Through Dash or Escape Dash
• Accessories

 

Safety Precautions and Disclaimer

Cusco USA Inc. builds parts which are for racing and therefore experimental in nature. These parts do not match your vehicle manufacturer’s specifications. Because of this, our parts do not come with any warranty.

Any warranties offered by brands other than Cusco USA Inc. are the responsibility of the manufacturer and not Cusco USA Inc.

Except where outlined on our warranty page for specific items, parts from Cusco USA Inc. are sold “as is” and without warranty of any kind.

Cusco USA Inc. EXPRESSLY DISCLAIMS all implied warranties, including all warranties of merchantability or fitness for a particular purpose. 

Purchaser acknowledges that no representations have been made to him regarding these parts, including but not limited to any representations as to their quality or performance, and that he (or she) shall be responsible for and bear all costs of repair or replacement of any defect in or failure of these parts.

Any and all roll cages may impact, and modify, or defeat the safe and intended functions of production road car equipped with Passive Restraints, SRS Airbags, Crumple Zones, and other systems and inherent design features.  Please use caution to disable SRS Airbag systems which may be interfered or rendered dysfunctional by the placement and addition of these cages.

Purchaser, Installer, and User acknowledges that installation of these parts may cause his (or her) vehicle be unable to be lawfully used on public highways in the United States of America as well as other locals and regions, and assumes al risks and expenses thereof. All suggested modifications and recommendations are intended solely for use on vehicles participating in off-highway competition events. Purchaser acknowledges that all manufacturer vehicle warranties are voided if the vehicle is used in any Competition events. The purchaser accepts all responsibility for modifications to said vehicle(s) and all potential risks.

There are a wide range of roll cages available for a broad range of cars, suitable for street, track and competition use. As Cusco has a long line of racing heritage, the structures are based on feedback straight from the competition field, so you can be assured you are receiving quality products.

The standard construction for a Cusco cage is a 40mm diameter tubular frame with joints that can either be welded or bolted. Each leg has a base plate that can be welded into the vehicle or bolted to the body. Cusco’s roll cages are made to order and each one is custom made to fit the driver preference.

** It is extremely critical that any bars positioned within proximity and in front of the driver/passenger areas be covered with approved padding for ensuring safety of the occupants.

 

1. Bolt in or Weld in?

 

Bolting the roll cage to your vehicle:  makes it a much easier job to fit and gives you the ability to remove it

Welding the roll cage into your car:  is lighter than bolting the cage in gives better rigidity and safety

 

2. Choosing the Material

Cusco D1 Chromoly/CrMo (Chromium Molybdenum)

33% Lighter than Steel Cages : The D1 roll cage uses the material Chromium Molybdenum for the pipes, making it around 33% lighter than the conventional Steel cages.Lightweight Joints: Lightweight joints are used to increase safety with competition roll bar designed layout

Withstands Light-Medium Impact: Being strategically mounted, and designed from extensive hands on experience, the D1 roll cage has the ability to absorb light to medium impact without jeopardising the structural integrity of the cage.

Safety 21 CDS (Cold Drawn Seamless) Steel

Affordable: This roll cage is cheaper than the ‘D1 CrMo’ version; beneficial to those on a restricted budget.

Withstands Heavy Impact: The roll cage is cleverly designed and constructed of carbon steel thus the structural integrity is not threatened by heavy impact; recommended for heavy track use.

Higher Rigidity & Safety: As explained above, the material can withstand heavy impact making the roll cage safer all round.

3. Selecting Manufacturer and Chassis Code for Specific Applications

 

Go by chassis code, since Cusco is manufactured in Japan so not all cars have the same production line and name as its overseas counterpart. In order to ensure the right fitment for your car, you must go by chassis code which can usually be found in your vehicles papers (the code is incorporated in the cars VIN No. or Firewall Stamped Plate/ Door tags)

 

4. Got a Sunroof or Convertible Top

 

Purchase a sunroof compliant roll cage

Cusco only makes a small number of ‘sunroof compliant’ cages.

If you have a sunroof and do not purchase this type of roll cage, you will have to make a basic modification in order for the cage to fit your vehicle.

Modify roll cage

To modify a roll cage, not designed for a vehicle with a sunroof, you would need to shorten each leg of the roll cage (to compensate for the thickness of the sunroof).

NOTE: Fitting a roll cage may mean the sunroof no longer opens.

 

5. Through Dash or Escape Dash

 

If you choose to purchase a roll cage 6 point or higher, you have the option to escape the dash or go through the dash.

Through Dash – (‘A’ pillar bar goes through the dashboard) 

Maintains Rigidity and Safety

Installation should be carried out by a professional

Escape Dash

(‘A’ pillar bar bends around the dashboard)

Easier to install

Decreases Rigidity and Safety

Not recommended for track cars

6. Choosing the C Pillar Bar Style

 

Choosing the style of your C Pillar bar is just another technique to ensure the roll cage suits your needs to the best it can. There are currently 3 styles available:

Window Style

The C Pillar bar is bent out and runs along the edge of the rear window going around the rear seats.

• Predominately used on 2-door vehicles as it ensures their rear seats are still accessible.
• Allows you to keep your car as close to stock as possible.

Roof Style

The C Pillar bar runs along the edge of the roof and down the C Pillar, over the rear seats, to the C Pillar mounting position.

• Predominately used on 4-door vehicles as it ensures the rear seats are easily accessed & left intact.

Race Style

The C Pillar bar runs directly through the rear seats (the shortest distance between the B Pillar Bar to the C Pillar Mounting position).

• The sturdiest configuration for the C Pillar bars
• Requires the removal of rear seats and interior trims.
• Recommended for 2-seater vehicles and regular track users

7. The C Pillar Bar Mount Position

 

The position where the C Pillar bar will mounted is pre-determined by Cusco (for each individual car) as, with their kn0wledge and experience, they can ensure the position gives maximum strength and safety.

 

8. Number of Mounts

 

The number of points determines the roll cage’s size and number of bars. A general rule is: anything below 5 point will only have B and C pillar bars; anything above 6 point will have A, B and C pillar bars (see image). Since there is no universal pattern amongst roll cage manufacturers, the mounting point system is easy.

View the chart below to decide how many points you prefer:

Cusco D1 Chromoly 4-8 point Rollcages

 

Cusco Saftey21 4-15 point Rollcages