Help! PPI Roll Bar Issue

[bz888]

Has anyone actually installed this PPI Roll Bar???
We are having issues.

Installation instructions read as per below:

12) With bar still in place, use upper mount holes as guide to drill 3/8" holes
through rear firewall. Note that firewall is twin-walled so use care to keep
bit straight and penetrate both walls
13) From engine compartment, use Uni-bit to enlarge holes to 3/4" ON
ENGINE COMPARTMENT WALL ONLY. This is to allow aluminum spacers
to be installed
14) Install upper-plates in engine compartment (see photo for proper
hardware placement)

Issue is with Point 12. The section of the firewall which lines up with the mounting plate is actually single wall and not dual wall! See picture below.

Therefore, since it's single wall we need to consider the following:

1. Why did PPI provide Spacers, when the actual position of penetration into the firewall, is a Single Wall only?
2. If PPI expects the roll bar firewall plate to line up the box section in yellow which is dual wall, then they obviously have never installed one. It's impossible!

So, we have to stop work until we clarify this issue with PPI USA or OEMPlus.

Anyone installed before? Any assistance would be great!

[gazza1]

Mate you must be feeling like the first wagon heading west into the wild frontier 200 years ago.

With Rollcage , Airbags , and Harness Mounts etc...

I would call on all forum members and sponsors to give as much assistance or knowledge to Bz as you can as he really wants to share the A-Z for those that follow.

Sharing knowledge is what this forum is best at

[mngolfer]

I would call the owner of PPI US Mitch Clay. His office number is (432) 682-4484. PM me for his cell phone number. He was very helpful to me on some questions I had. They have a technical team on hand to answer questions at their office number.

[FiftyPence]

It seems you currently have the rollbar at approx 90 degrees to horizontal in the vehicle, is it possible that it is supposed to be at say 85 degrees leaning back which might then allow the brackets to line up in the yellow section?

[ignomini]

Possibly silly question, but is the bar intended to mount with the interior panels in place? While I would prefer the center mounts would run down to the horizontal shelf below, in any case, the center mount should not be bolted down over the interior panel. At a minimum, you should cut out holes for the mounting plates. The bar should be mounted metal to metal. As mentioned by FiftyPence, if the bar is rotated back, I suspect the mounts would hit near the top of the double wall panel.

[bz888]

I would call the owner of PPI US Mitch Clay. His office number is (432) 682-4484. PM me for his cell phone number. He was very helpful to me on some questions I had. They have a technical team on hand to answer questions at their office number.

Thanks MN, I'll try call him now!

[bz888]

Hmmm, tried the number and just got an answering machine...

[bz888]

As you can see here in the Audi Repair Guide the area in Yellow is single wall.
The boxed "Dual Wall" section is WAY below the Yellow area.

No amount of sliding or moving the roll bar would allow us to reach that section.
Also, the plates wouldn't be flush against firewall...

This is soo frustrating, looks like my workshop will have to create a custom install and strengthen the area substantially!!!!

[bz888]

Surely Bodhii and Desperado can help out?? They've had this installed!!

[OEMplus.com]

V8 and V10 are different, so bodhii and desperado will not be helpful...

Nick, did you get the email I forwarded you? Leave the spacers out and you should be fine.