Some people here make it sound like this is realy dumb and it will reduce the effectiveness of the roll cage. I don't think that will be the case. Comments like trust my life to it or receiving the Darwin award. I started this post seaking comments and that is what I got. I do thank all that responded.

Please read article below.
General Motors, Toyota, and Renault
tested hollow tubular members that were filled
with a rigid polyurethane foam. The
technology is basically the insertion of the
polyurethane liquid within the thin-sheetmetal
tubular structure, then allowing the liquid to
expand and fill all voids as it hardens.
Such foam-filled members showed an
increase of about three times their original
bending strength and compressive strength, at
a very negligible weight increase. Various
models by Ford (Windstar minivan, Falcon in
Australia), Toyota (Lexus LS400), Infiniti,
and Nissan (Altima) have utilized such foamfilled
members to increase the strength of roof
support pillars.

Sounds worth a try if you have the time and patience to do so. However it should only be looked at as an added bonus and not to be a life saver.

Well we've all learned some new things about structural foam. That's what's great about forums like this.

__________________
_______________________________

Now a 2-Rzr household.
Romeo, MI
http://tinyurl.com/8ltm8
______________________________

[quote=walker411;45827]Some people here make it sound like this is realy dumb and it will reduce the effectiveness of the roll cage. I don't think that will be the case. Comments like trust my life to it or receiving the Darwin award. I started this post seaking comments and that is what I got. I do thank all that responded. QUOTE]


I think maybe I was not that clear. So let me put it is way to you ... There is nothing you can do to stock cage with foam, that will make it safe enough to protect your life in most condition.

Can you make a 1 3/4 or 1 1/2 1020 DOM or Chromalloy tub cage strong enough to protect you life in most cases? ..."YES"

Does foam make things stronger? ..."YES"

Would I as a metal fabricator ever use foam in anything? ... It wouldn't be my first choice, not all ... but most A-B Foam ... that the average Joe can buy ... is extremely flammable and gives off some lovely things to breath when on fire.

Can you make sheet metal structures really strong with foam? ... YES ... but I like Dimple Dies , there not as messy and look really cool.

I am not saying that it wouldn't increases the strength. It would as you have shown the data on. Is the amount that it would increases on the stock cage is so small when you are talking about 50,000 or 65,000 psi tube(stock Polaris) ... what do you gain ... maybe 1000 psi ... and that is if you could get it in every void in the tube also.

Is 1020 DOM or Chromalloy tubing stronger then the stock tubing used? ...YES ... almost twice as strong!

I was being so blunt ... so the members this forum ... don't think that it is a cheap way to make the stock cage really strong. A 1000 psi stronger is not allot!

And I apologize for being so rude on a honest question?