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Welding in another cross-member behind seats for racing harness

Jonathan O'Hara

Active Member
J
Hi guys,

I've welded in a cross-member behind the seats that is around a foot above the stock one and want input on whether my welds are OK enough to rely on.

I added the cross-member because when I put my seats (from Procar) and racing harness in, the straps sit on top of my shoulders, and then straight down to the stock cross-member. Because I'm relatively tall (6'2), the eyelets on the seats don't touch the harness straps or provide any support. I understand if I were in a roll-over, the harness running straight down from the top of my shoulders to the stock bar could compress my spine and do bad things. I think the rule is that straps are supposed to go straight back from the shoulders, +/- 20ish degrees.

With my new bar they do. But ... I'm a pretty new welder, and after welding this bar in, I now have a MUCH greater respect for professional welders who do good welds in a variety of positions (overhead, standing on head, etc.). I've attached pictures of the cross-member, and for illustration, the best weld (outside passenger) and the worst weld (center joints). As background, this was a MIG weld with 0.030" wire and a HF Vulcan Omnipro 220. My fit-up of the tubes was OK, maybe like 0.070" gap on the bottom of a tube was the worst.

Are my welds good enough to rely on, or am I better off tying in the stock cross-member (that is excellently welded by the guys at DF) and just ignoring the 20 degree rule for racing harnesses?

I figure most of you guys on this forum will at least sympathize with my desire to do as much as possible myself, though I do realize there's a point where serious safety concerns are more important.

Thanks for any input!

PS: For any curious SS/SC guys, that's a TVS1320 installed. I haven't run with it yet, but I'm hoping for good things.
 

Attachments

  • 1 - Full crossbar.JPG
    1 - Full crossbar.JPG
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  • 5 - outside passenger joint - front.JPG
    5 - outside passenger joint - front.JPG
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  • 5 - center joints - back.JPG
    5 - center joints - back.JPG
    243.7 KB · Views: 737
Ross
If it was my kit, I would strap myself to your bar. You have done well for a beginner welder. My opinion on your welds is that they are good... but it is just a visual guess. You could always test them for strength. The human body can only take a limited amount of seat belt restraint... I would guess your bar would hold many times that load. To test them take a ratchet strap and pull on the bar... pay attention to when the frame starts 'springing' and deforming towards the load. Since you don't want to do destructive testing, stop testing at the point the frame starts being sprung. Probably around 2000 pounds to 5000 pounds. Bet your welds are strong enough to bend the frame first. Just a guess, but I have done a fair amount of destructive weld testing. Legal disclaimer is in the fine print...
 
JSATX
My straps also have an extreme angle to the tube, but I’ve just kinda ignored it. Another member made a cross tube that bolts into the upper seatbelt mounting hole, which would be a good option if you didn’t want to weld to another bar to the frame
 
B
All of the info I found seems to say that the straps need to either be level or no more than 20 degrees below level. Won't the height of that bar put the strap mounting point above level?
 
J
My straps also have an extreme angle to the tube, but I’ve just kinda ignored it. Another member made a cross tube that bolts into the upper seatbelt mounting hole, which would be a good option if you didn’t want to weld to another bar to the frame

That is a simpler idea. If I hadn't been seen keen to weld everything in sight, I might have tried to think up other solutions!


All of the info I found seems to say that the straps need to either be level or no more than 20 degrees below level. Won't the height of that bar put the strap mounting point above level?

On further review, I think you're right about level or minus 20 degrees. I thought I'd seen one example where there was a plus or minus, but almost everything says level or below. Thank you for pointing that out.

I aimed for that bar to be level with my shoulders given my height, so I'm going to double that I'm alright, and think about how to safety address other shorter drivers. Maybe move the harness to the lower bar because then the seat belt eyelets will be the limiting factor on the downward angle.
 
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