How to Bend Roll Cage Tubing

Written by sanne godfrey
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How to Bend Roll Cage Tubing
Bending the roll cage tubing can be very difficult. (Ready to Rock and Roll image by John Sfondilias from

Creating your own roll cage can come with several complications. One of these complications can be the bending of the roll cage tubing. The bars need to be shaped on a special bender that does not wrinkle or kink the tubing in the bend area. Harold Pace from says that all bending must be done "cold" and the radius of each bend is important, as too tight a radius will weaken the bend. The radius should be at least three and a half times the diameter of the tubing.

Skill level:

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Things you need

  • Paint pen

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  1. 1

    Mark where the tubing needs to be bent on the tubing that you want to use for the roll cage. Because of the texture of the tubing, it is important to use a paint pen to avoid accidentally removing the mark. The tubing will be touched frequently and chalk could easily be removed in the process if you're not careful; the paint markings will remain visible on the tubing longer.

  2. 2

    Draw the tubing through a stationary counter-bending die onto a fixed-radius former die. It is important to draw the tubing straight through to avoid any unwanted bending.

  3. 3

    Sand the tubing and make sure that the angle is correct before using this tubing in a roll cage. Make sure the tubing is smooth and sanded before use; this will be an added safety feature on the vehicle.

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