One of the fun parts of building race cars is putting the finishing touches to a roll cage. This time it’s adding the gussets to our Time Attack 180sx. “Gusset plates not only serve as a method of joining steel members together but they also strengthen the joint”. That’s exactly what we’re doing here, gussets down the A and B pillars, gussets to strengthen the main hoop and of course gussets to strengthen the door bars. Attaching the cage to the car down the pillars helps to keep the car as rigid as possible and joining the cross bars on the main hoop and door bars prevents them from twisting or breaking in case of an accident or rollover. It’s not a hard task, like all things in fabrication; measure! We measure out the size of the gusset, make a template out of cardboard then transfer the outline to some 1.6mm sheet steel. After cutting out and cleaning up the edges, holes are drilled to the appropriate size of our dimple dies then they’re dimpled in a press. The dimpling compresses the metal so we can both remove weight from the gusset and increase it’s strength at the same time. So there you have it, gussets give that finishing touch to the structure of our roll cage and they look good too.