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Last Update: December 12, 2009

2004 Roush 442

Cathy Shalaby brought us her really nice 2004 Roush 442 to install a roll bar. Fond of road track racing, she and her husband wanted to be able to take the Roush out on the track and drive like Jack Roush designed it to be driven. One thing held them back – it’s a convertible and convertibles require a roll bar at any responsible road track – and that ‘classic’ light bar just doesn’t cut it.

To run on a road track, you have to have a qulaifying roll bar – at least a 4 point with minimum 1 ¾” DOM tubing. But how do you do that without sacrificing the cool appearance of the light bar? SMS came up with the answer. We engaged our friends at Mandrel Bending Solutions to bend us a custom main hoop that matched the profile of the light bar. We wanted it to blend in with the appearance of the car but still meet track requirements.

The main hoop was fitted to car and welded to base plates to provide a bolt-in installation.

The rear support bars had to fit inside and pass through the light bar therefore they had to mount slightly inside of where we normally place them. Our plates mounted on the rear vertical frame to provide both the angle and the stiffness necessary.

And here’s the final product ready for powder coating.

Now it’s time to clean evything up and make the new bar look as good as the rest of this car. We sent it over to our friend Gary Lamb at Extreme Powder Coating to get color matched to the classy leather Roush interior. Gary did a great job as evidenced by how well the final product looks.

One final touch – as mentioned the rear support bar had to sit a bit further inboard than we normally place it so it didn’t fit nicely between the seat back and frame – too much bulge in the seat back. So we had our interior specialist Bo do some minor surgery and fit the bar through the seat. He did a great job as always and it looks like factory.

We think this came out really well and the customer is very happy with it. We’re now working on a similar install in a new Shelby GT500 convertible.

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