Currently my "roll bar" is really more cosmetic than structural, but as I need to add a bar to run my harnesses over (to raise effective anchorage point) I need to strengthen the mounting points to make it a structural component and so keep IVA man happy.

Rear mounts look like this



With these I intend to move the mount below the existing brace for the harness mounts as this should provide sufficient load spreading, I think... 30mm x 4mm x 880mm


What I am stuck with is the front leg mounts which currently look as below, I hasten to add this not my handy work and something I have never really been happy with



Thoughts on this so far are to add a load spreading plate (5mm thick and 200x100mm) on the otherside directly opposite from where this photo was taken as use the existing unused hole and drill a second In between the two horizontal bolts to add strength there, but not sure what to do about the wooden wedge an those bolts? I don't have the ability or tooling to make up a metal replacement which would seem the ideal Option?


Last of all, how would you go about adding the required bar to this roll bar?



Could I simply get a suitable piece of tube and bolt it between the front two legs or would I need to get it welded in?

Thanks in advance

It is my understanding all fixing points need to be on the chassis and that design of bar you need to consider if it needs to be diagonally cross braced. I say this as the diameter of that tube looks a bit lean not to mention the gauge of metal which I have no knowledge of.

It's a monocoque chassis, so it is bolted to the chassis, but I fully appreciate it would need reinforcing. I could add a diagonal brace at the same Time if required.

Any more thoughts on this? The more I think about it the mor I think I need to add load spreading on the underside of the front legs, only problem beeping I have no idea how to access that area.

What thickness is the material of the bar you've got? To be blunt, it looks like such a terrible design/fitment that it can only have been intended as cosmetic, so it seems highly unlikely it's thick enough to be structural.

Honestly don't know material thickness for the bar.

Any other suggestions for how to raise the effective achorage point then?