Project: Harness Bar - PICS!

Project: Harness Bar - PICS! *UPDATE*

The last few times I've auto-x'ed my car, I've gotten a little frustrated with how much I float around in the seat. Side to side, the bolsters on the Bullitt seats are great, but getting on and off the gas so frequently throws me back and forth in the seat too much. Since I recently got laid off from my job, and money is tight, I figured while I'm searching for another design job, I'll keep my skills up. I decided that $300 for a Corbeau harness bar was ridiculous considering its just a few pieces of tubing and some brackets, so I'm making my own. Excuse my welding, sometimes it isn't pretty, I'm still learning. No better way than to get my hands dirty, right?

Here's what I've spent in materials so far:

$16 - 1.25" x 60" OD DOM tubing
$6 - 1/8" x 1.5" x 36" steel bar
$6 - 2 sawzall blades
FREE.99 - random metal for brackets that I had
FREE.99 - Grade 8 bolts

I began to document the process after I started welding so there is no pics of the very beginning. I started by bending both ends of the tube on roughly a 30*-35* angle with my hydraulic tubing bender. Then I cut each end on a slant and welded the brackets to each end. These brackets mount to the upper seatbelt bolts.





After drilling the holes in the brackets, I test fit everything and my measurements were just about spot on.

Next I made 2 right angle brackets that mount to the bottom of the main bar. These brackets will have a tube attached to each one that runs down to the lower seatbelt mount where I fabbed up another pair of brackets. There will be 2 holes drilled in each; one bolts to the seatbelt bolt, the other is where the downtube mounts.



It will be easier to see once I get it a little further along but I haven't gotten to making the downtubes yet.

The main crossbar is done, I just need to fab a small camera mount for the center, and paint it up. I'm thinking about a matte black wrinkle finish paint or bumper coating. Here's where I am as of today including a few pics of it mocked up in the car:











I have a set of black Simpson 5-point harnesses that my dad gave me from his old race car with like 5 track days on them. NHRA requires new belts every 2 years even if they are in perfect condition so he had some lying around. Saved me a nice $100!



I will be updating this thread as I continue the project. Enjoy!

Kornnut said:

Are you making a submarine bar to go with it for the lower belt?

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Nope. I'm probably gonna just drill a hole in the floor under the seat and put a plate under the car. Then put the bolt through the floor and through the plate. There won't be a lot of stress on that submarine belt, I might not even use it. 4 points will be more than enough for auto-x. I'm not installing these belts as a safety feature, I'm installing them so I stay put in the seat hahaha.

BurningRubber said:

That's awesome, I love seeing stuff like this.

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Thanks man, hopefully it comes out real nice when its done.

Thanks a lot guys! This is somewhat of a wakeup call to me. I am an honors graduate of the Savannah College of Art and Design with a BFA in Industrial Design. I got a job with a toy design company 2 months after I graduated, worked there for 3 months, then got laid off due to poor business...last to be hired, first to leave. While I loved the job, my true passion has always been getting my hands dirty and building things. I'm starting to realize maybe I should use my degree in a slightly different way.


Again, thanks for all the compliments! I should have some progress tomorrow as I ordered my rod ends from McMaster Carr last night and I should have them tomorrow. Hopefully I can get everything completely mocked up tomorrow and in primer.

Pics to follow, stay tuned.

N8Dogg98 said:

Wow, that looks great man... nice work. You definitely have one of the best cars on SN.

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Thanks so much, that means a lot!

UPDATE: Not much welding got done today, but I received all my rod ends and got some miscellaneous hardware to finish this thing up. I'm running into a snag right now because the triangular seatbelt holders that mount to the c-pillar slightly rub against the main tube. It rubs enough that the belt doesn't retract, and even with some washers to space it out, it still rubs. Back to the drawing board. I'll hopefully have some pics tomorrow.

Nope, sorry guys. I hit a little snag, then I was away for the weekend and just got back today. Turns out the main bar hugs the seatbelt holder just a bit too close and the seatbelt rubs on it hardcore, to the point where the belt doesn't retract. I need to modify the side tabs a bit, then I should be on the home stretch. Probably won't get anything done on it tomorrow or Wednesday unfortunately because its supposed to pour outside, and the only 220v outlet we have is in the garage...which is now occupied with my dad's cars which are in pieces for the winter.

I will definitely post up some updates in a few days...hopefully.

UPDATE:

I've been really busy the last week or so and the weather has been really cold to weld but yesterday it was a little warmer and I made a ton of progress.

I fixed the side tabs by welding another piece on the back and drilling the hole a bit higher up. This fixed my problem of the factory belts rubbing against the main bar. Then I welded the thin bars on the top of the main bar to hold the shoulder belts in place. I mis measured buy an inch on both sides so I have to cut and relocate them next time I go out to weld. What a n00b! Anyway, then I bent the 2 downtubes on my tubing bender and hammered 3/8" bolts into the ends so I could thread the rod ends on.

All I need to do to finish the bar is relocate the shoulder strap "holders", and weld the bolts into the downtubes. I borrowed my friends little 1" disc grinder/sander to smooth out some of the welds, then I'm going to prime it and paint it with VHT black wrinkle finish paint. I bought the paint last week and did a test swatch on a scrap piece of metal, and it looks pretty awesome. It might end up being a little glossier than I wanted so I might spray some semi-gloss black on top of it, but the wrinkle finish will remain.

Here's some pics as I went along. Sorry for the quality, they are from my Blackberry. I'm always so nervous to bring my SLR out when my hands are dirty, and I always forget to get a camera until I'm almost done haha. Enjoy!

txredgt said:

Any finished pictures of this project stprorolla?

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Unfortunately, not yet. Since I last worked on this project, I relocated and started a new job. The welder is back at my parents house so I don't get to use it much. Hopefully within the next few weeks I can wrap things up with this project and get it to the powdercoater. I'll post pics for sure when its complete.

just_a_guy84 said:

Let me start by saying that I am not trying to be a jerk...but, please, go back over your welds. Make sure you have complete fusion on both pieces of material. The picture of the tubing and brackets shows some incomplete fusion, that will result in a much weaker finished product. I weld and machine for a living. I love seeing people jump in and learn a new skill, but I feel obliged to provide constructive criticism. Take your time on stuff like this, get it right the first time, every step you take to raise your welding ability the better your project will turn out in the long run. Anyone can weld, but it takes time and practice to weld well. Learning what to watch for and what to avoid. Again, I am not trying to come off as a jerk, or knock your ability, a lot of your fabrication looks really good. I just see some minor points that if addressed would make a good project great.

I would be glad to kick out some tips and tricks if you wanted to hear them.

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Thanks for the advice. I am thinking about rewelding some of these parts on here because the welds weren't as clean as I would have liked. I guess if you have any tips on the best way to get the tig into the tight spots, like where the main tube dips down right after its welded to the side mounting tabs...right underneath there is hard to get the welder in there without extending the tungsten, but then I get improper shielding. Suggestions? Thanks!