If you're building a roll cage—whether for off-road, drag racing, drifting, circle track, or UTVs—your tube sizing and joint angles matter. They affect weight, strength, weldability, and whether your cage will pass inspection.
This guide breaks down standard tube sizes, common cage angles, and includes easy-to-read charts you can embed directly into your fabrication workflow.
Common Roll Cage Tube Sizes (DOM & Chromoly)
1. DOM Tubing (Most Common)
| Vehicle Type | Typical Size | Wall Thickness |
|---|---|---|
| UTV | 1.50" | .095–.120 |
| Drift / Track | 1.75" | .095–.120 |
| Off-Road / Baja | 1.75" | .120 |
| Ultra4 / Heavy Duty | 2.00" | .120–.188 |
2. Chromoly (4130)
Stronger but needs TIG welding and proper heat control.
| Use Case | Typical Size | Wall Thickness |
|---|---|---|
| Drag Racing | 1.625" | .083 |
| Road Race | 1.75" | .083 |
| Ultra-Light Build | 1.50" | .083 |
Notching Angles in Roll Cage Design
Cages rarely use only 90° joints. More often, you'll see:
- 45° → node triangulation
- 60° → roof bars
- 15°–30° → downbars
- Compound angles → A-pillar and B-pillar intersections
Common Roll Cage Angle Reference Chart
| Joint Location | Typical Angle | Notes |
|---|---|---|
| A-Pillar to Roof | 10°–30° | Depends on windshield rake |
| Roof Diagonals | 30°–45° | Triangulation necessity |
| Door Bars | 0°–20° | Keep low angles for strength |
| Harness Bar Tie-In | 90° | Straightforward cope |
| Rear Stays | 20°–45° | Depends on chassis layout |
Tube Coping Tip for Cages
If you're dealing with compound angles (almost always), use a template generator so both angles are baked into the contour. It saves hours and produces a tighter, safer fit.
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Our Pipe Coping Template Generator handles compound angles automatically. Generate printable templates for any roll cage joint in seconds.
Try the Template Generator →Conclusion
Choosing the correct tubing size and understanding cage geometry is the difference between a cage that's safe—and one that gets rejected at tech. Use these charts as quick references, and rely on accurate notching templates to ensure every joint fits perfectly.
Building a roll cage? Start with the right tube size, measure your angles carefully, and use proper templates for every cut. Your safety depends on it.